Vacuum Material Transfer System for Pothole Patching
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Solution Overview
Problem
Existing pothole patchers face issues with aggregate clogging, high maintenance costs, and safety risks due to pressurization and the use of moving parts like augers and vibrators, which can lead to component failure and operator safety hazards.
Innovation Solution
A vacuum-operated material transfer system that creates a vacuum to pull aggregate out of the hopper and into a flow path of forced air, eliminating the need for pressurization and moving parts, and allowing for controlled and reliable aggregate delivery to the boom assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hopper is pressurized to prevent aggregate clogging and facilitate steady flow, then aggregate flow reliability is improved, but device complexity and cost increase due to additional sealing components and heavy duty construction
Solution Approach 1:
Instead of pressurizing the hopper to force aggregate out, the invention inverts the approach by creating a vacuum at the outlet to pull aggregate out. This eliminates the need for complex pressurization sealing systems while achieving reliable aggregate flow.
Solution Approach 2:
The invention replaces the mechanical pressurization system with a vacuum-based system using a vacuum pump and nozzle assembly, eliminating the need for heavy duty hopper construction and complex sealing mechanisms.
2Reliability
If a gasket is provided between lid and hopper to enable pressurization, then hopper sealing is improved, but maintenance requirements increase due to gasket wear and replacement
Solution Approach 1:
The invention removes the gasket and lid assembly entirely by using a vacuum nozzle positioned at the hopper outlet. This eliminates the sealing interface that requires maintenance while still achieving the goal of controlled aggregate delivery.
3Productivity
If forced air is routed to pressurize the hopper, then aggregate flow is improved, but energy consumption and pump load increase
Solution Approach 1:
Instead of using forced air to pressurize the hopper, the invention uses a vacuum pump to create negative pressure at the outlet, pulling aggregate through the system without adding load to the hydraulic pump.
Solution Approach 2:
The invention uses a vacuum pump to create a pressure differential that draws aggregate through the hopper and delivery system, providing reliable flow without the energy costs associated with pressurization.
4Ease of operation
If an auger or screw conveyor is installed in the hopper to guide aggregate, then aggregate flow control is improved, but device complexity and maintenance costs increase due to additional moving components
Solution Approach 1:
The invention removes all moving components from the hopper by using a vacuum-based extraction system. Aggregate flows freely under gravity and is pulled out by the vacuum, eliminating augers, conveyors, and their associated maintenance requirements.
Solution Approach 2:
The hopper design allows aggregate to flow freely without mechanical assistance. The vacuum system at the outlet creates sufficient suction to pull aggregate through without any moving parts inside the hopper, making the system self-regulating.
5Strength
If heavy duty components are used to withstand pressurization, then hopper strength is improved, but device weight and cost increase
Solution Approach 1:
The invention inverts the pressure approach by using vacuum instead of pressurization, eliminating the need for heavy duty components designed to withstand high pressures while maintaining structural integrity.
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 provides a reliable, low-maintenance, and efficient method for aggregate transfer, reducing the risk of clogging and component failure, while enhancing operator safety and ensuring consistent delivery of the aggregate-emulsion mixture to the pothole.
Implementation Method 1
a reduction nozzle provided between the air source and the vacuum chamber, the reduction nozzle creates a vacuum in the vacuum chamber by reducing the pressure of the forced air entering the vacuum chamber
Implementation Method 2
creating a vacuum that pulls heavy aggregate, such as gravel or crushed rock, out of a hopper
Implementation Method 3
a flow path of forced air that is provided by an air source, the forced air entrains and carries the aggregate through a conduit and to a boom assembly
Data Source
AI summary
Embodiments of the present invention relate to systems and methods implemented in a pothole patching system for creating a vacuum that pulls heavy particulate, such as gravel, out of a hopper. For example, according to an embodiment, a vacuum body having a vacuum chamber formed therein is positioned proximate to an opening of the hopper. A moveable slide gate is provided between the vacuum chamber and the opening of the hopper. The slide gate moves between open and closed positions for permitting and blocking communication between the vacuum chamber and the hopper. A reduction nozzle is provided between an air source and the vacuum chamber. Forced air flows from the air source, through the reduction nozzle, and into the vacuum chamber. The reduction nozzle reduces the pressure of the forced air entering the vacuum chamber, and thereby creates a vacuum in the vacuum chamber. When the slide gate is in the open position, this vacuum pulls particulate from the hopper.