Vibration System for Concrete Pipe Molds
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Solution Overview
Problem
Existing vibration systems for adjustable concrete molds in the dry-cast method fail to provide adequate vibration, leading to bowing of the mold structure, incomplete concrete compaction, and undesirable surface defects like 'slabbing off', especially when producing products of varying sizes.
Innovation Solution
A vibration system featuring two vertically spaced-apart coupled vibrators mounted in opposite corner panels of the core, with reinforced shelves and gussets, creating a rigid structure that vibrates the entire core mass instead of flexing individual panels, ensuring uniform vibration and improved concrete compaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If adjustable forms with removable panels are used, then manufacturers can produce products of different sizes, but the panels will loosen and separate under central core vibration
Solution Approach 1:
The core is divided into multiple panel sections that can be assembled in different configurations. Each panel is independently vibrated by individual vibrators mounted on both the jacket and core, allowing the segmented structure to flex and transmit vibration without loosening connections.
Solution Approach 2:
Individual vibrators are mounted on both the jacket and core to provide mechanical vibration that compacts concrete while allowing the adjustable panels to flex. The vibration frequency and amplitude are controlled to compact concrete without causing panels to loosen or separate.
2Ease of manufacture
If the form set is built flexible enough to vibrate the concrete, then vibration can be transmitted to the concrete, but the form will bow at the center creating surface defects
Solution Approach 1:
Vibrators mounted on both the jacket and core provide mechanical vibration that compacts concrete effectively. The vibration system is designed to transmit vibration through the concrete without requiring the form to flex or bow, maintaining structural rigidity while achieving proper compaction.
Solution Approach 2:
The vibration parameters (frequency, amplitude, duration) are optimized to achieve proper concrete compaction without requiring the form structure to flex. The vibration intensity is controlled to prevent bowing while ensuring adequate consolidation of the concrete mixture.
3Ease of manufacture
If small individual vibrators are mounted on both jacket and core, then vibration can be transmitted to concrete, but adequate vibration is not provided for proper compaction
Solution Approach 1:
The vibration systems of the jacket and core are merged and coordinated to work together. Vibrators on both components are synchronized to provide combined vibration that delivers adequate compaction force throughout the concrete, addressing the insufficiency of individual small vibrators.
Solution Approach 2:
Multiple small individual vibrators mounted on both the jacket and core provide distributed mechanical vibration. The combined vibration from multiple sources achieves adequate compaction force and distribution throughout the concrete form, overcoming the limitation of single-point vibration.
4Manufacturing precision
If a rigid core is used for central vibration, then vibration can be effectively transmitted, but the core cannot be adjusted for different product sizes
Solution Approach 1:
The core is segmented into multiple rigid panel sections that can be assembled in different configurations. Each panel maintains rigidity for effective vibration transmission, while the segmented design allows adjustment of the overall core size and shape to match different product requirements.
Solution Approach 2:
The core transitions from a fixed rigid structure to a dynamically adjustable assembly. The rigid panels are connected in a way that allows reconfiguration for different product sizes, combining the vibration transmission efficiency of rigid structures with the adaptability of adjustable forms.
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
This solution provides superior concrete compaction and surface quality by maintaining mold rigidity during filling, reducing defects like bowing and slabbing off, while allowing for cost-effective production of various product sizes without the need for multiple mold sizes.
Implementation Method 1
concrete vibration is necessary to consolidate and compact the concrete in the mold prior to curing
Implementation Method 2
The shelves are reinforced by gussets that are welded to the exterior walls
Data Source
AI summary
A vibration system for concrete pipe making machines using the dry cast method and which employ adjustable molds comprised of corner panels joined to intermediate panels. Two coupled vertically spaced-apart vibrators are mounted in two opposite corner panels of the mold core. The vibrators are mounted on shelves welded to the interior of the walls that form the mold surface. The shelves are also welded to vertical end walls that extend inwardly to form the box-like corner panel. The corner panels and intermediate panels are secured together by removable fasteners that join the vertical end walls of the corner panels to the corresponding vertical end walls of the side panels. The joined corner panels and side panels provide a rigid core structure similar to a solid core and allow the entire core to become the vibration structure.