Vibrating Table Wear Measurement for Concrete Block Production
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Solution Overview
Problem
Existing vibration devices for concrete production require frequent manual inspection and readjustment of impact bars, which is complex, risky, and necessitates shutting down the production line, leading to inefficiencies and wear inconsistencies.
Innovation Solution
A measuring device with automated distance measurement capabilities is integrated into the vibration device, allowing for non-invasive, automated detection and adjustment of wear on impact bars and vibrating tables, eliminating the need for manual intervention and production line shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection and readjustment of impact bars is performed, then wear on impact bars and vibrating table can be reduced, but production line must be shut down and inspection process is complex and time-consuming
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated optical measurement system. The measuring device uses optical sensors and evaluation electronics to automatically determine vertical distances between impact bars and vibrating table, eliminating the need for manual caliper measurements and readjustment operations.
Solution Approach 2:
The measuring device enables self-monitoring of wear conditions without requiring production line shutdown. The system automatically detects wear on impact bars and vibrating table wear strips, providing continuous feedback that allows operators to schedule maintenance during planned downtime rather than forcing unplanned shutdowns.
2Measurement precision
If manual inspection with calipers is used, then wear measurement can be performed, but the process is risky and requires partial disassembly of components
Solution Approach 1:
The patent replaces manual mechanical caliper measurements with an automated optical measurement system. The measuring device uses optical sensors positioned above the vibrating table to non-contactively determine vertical distances, eliminating the need for physical contact and partial disassembly of components.
Solution Approach 2:
The patent introduces an intermediary optical measurement system that bridges the gap between the impact bars/vibrating table and the operator. Instead of direct manual measurement requiring access to tight spaces, the optical sensors act as intermediaries that can measure from a safe, accessible position above the equipment.
3Reliability
If impact bars are not correctly adjusted, then wear on wear strips accelerates, but consistent quality in precast concrete products cannot be ensured
Solution Approach 1:
The patent implements a feedback mechanism where the measuring device continuously monitors the vertical distances between impact bars and vibrating table wear strips. The evaluation electronics process this data to detect wear patterns and provide feedback to operators, enabling timely readjustment before wear accelerates or product quality deteriorates.
Solution Approach 2:
The measuring device enables preliminary detection of wear conditions before they lead to accelerated wear or quality problems. By continuously monitoring vertical distances, the system can identify trends and alert operators to perform preventive maintenance before critical wear thresholds are reached.
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 solution enables efficient, error-free, and cost-effective inspection and adjustment of impact bars, reducing wear and ensuring consistent product quality while minimizing downtime and operational costs.
Implementation Method 1
The measuring unit can be moved successively to predefined measuring positions and/or to measuring positions determined during the guiding process over the impact bars and the vibrating table. Using the measuring unit, the vertical distances from the upper surfaces of the impact bars and/or the upper surfaces of the vibrating table to reference positions, which result from the height of the measuring unit at the respective measuring positions, can be determined.
Data Source
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AI summary
The invention relates to a measuring device (1) for a vibrating unit (24) of a concrete block production plant. Such a vibrating unit (24) typically has a vibrating table (20) and impact bars (22) arranged parallel to each other and parallel to the floor with respect to their longitudinal axes. The measuring device (1) has at least one measuring unit (2a, 2b) for distance measurement. The measuring unit is arranged above the vibrating table and the impact bars, and the measuring unit (2a, 2b) can be guided orthogonally to the impact bars (22) and parallel to the floor by means of a guide unit of the measuring device. According to the invention, the measuring unit (2a, 2b) can be approached successively to predefined measuring positions and/or to measuring positions determined during the guiding process via the impact bars (22) and the vibrating table (20).Using the measuring unit (2a, 2b) the vertical distances from the tops of the impact strips (22) and/or the tops of the vibrating table (20) to reference positions, which result from the height positions of the measuring unit (2a, 2b) at the respective measuring positions, can be determined.