Rotating Drum Mat Forming System for Erosion Control
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Solution Overview
Problem
Existing methods for forming flexible erosion control mats, such as those described in U.S. Pat. No. 6,793,858, require improvements in manufacturing efficiency and product quality, particularly in retaining soil on surfaces adjacent man-made structures until vegetation matures.
Innovation Solution
A flexible mat forming system that uses a rotating drum with mold cavities and a hopper to deposit a hardenable paste onto a sheet of geogrid mesh, allowing the mesh to become embedded in the paste as it hardens into blocks, forming a sturdy tied block mat suitable for erosion control on various surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible mat structure is made by depositing concrete in mold cavities and embedding mesh structure, then erosion control effectiveness is improved, but manufacturing efficiency and productivity are reduced
Solution Approach 1:
The mesh material is pre-positioned on the drum surface before concrete deposition, and the hopper is pre-configured with aligned openings matching the mold cavity pattern. This preliminary arrangement eliminates time-consuming alignment operations during production while ensuring proper embedding of the mesh in the concrete blocks for effective erosion control
Solution Approach 2:
The system maintains continuous production by keeping the hopper openings continuously aligned with the rotating mold cavities, allowing uninterrupted concrete deposition and mesh embedding. The synchronized rotation and deposition create a continuous manufacturing process rather than batch operations, significantly improving productivity while maintaining product quality
2Manufacturing precision
If the hopper opening is positioned to align with mold cavities, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The hopper is designed with multiple discrete openings corresponding to individual mold cavities, allowing each opening to be independently positioned and aligned. This segmentation enables precise alignment with each cavity while keeping the overall structure modular and manageable, rather than requiring a single complex adjustable mechanism
Solution Approach 2:
The drum surface provides a curved, rotating platform that naturally guides the alignment between the hopper openings and mold cavities. The rotational motion and curved geometry simplify the alignment process compared to linear arrangements, as the circular path automatically maintains consistent spacing and positioning throughout the rotation cycle
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 increases the quality and efficiency of flexible mat production, enabling the creation of a drivable, erosion-control surface that can be applied to airport runways, roadbeds, and waterways, effectively retaining soil until vegetation matures.
Implementation Method 1
depositing a hardenable paste through the opening and into the mold cavities such that the sheet of mesh material becomes embedded in the hardenable paste over the mold cavities; displacing the panel from the mold cavities as the hardenable paste hardens in the mold cavities into blocks
Data Source
AI summary
In an exemplary embodiment, a flexible mat forming system includes a rotating drum having a plurality of mold cavities about an outer periphery thereof; a hopper positioned adjacent the drum, the hopper shaped to receive a hardenable paste and deposit the hardenable paste into successive mold cavities of the plurality of mold cavities facing the hopper, as the drum rotates relative to the hopper; wherein the hopper includes an opening shaped and positioned to align with the mold cavities facing the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper.