BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
FIG. 1 is a top view of the finishing machine over a concrete casting bed;
FIG. 2 is an end, partially perspective view showing the finishing machine over a moving bed;
FIG. 3 is an end view showing a bed positioning mechanism;
FIG. 4 is a partial perspective view of the finishing machine;
FIG. 5 is a top view of the finishing machine;
FIG. 6 is a side view of the finishing machine showing the press patterning;
FIG. 7 is an end view of the finishing machine showing the press; and
FIG. 8 is an end view showing the press pattern detached.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, the form of the finishing machine used in connection with a moving casting bed 10 is employed is shown. Moving casting beds 10 are well known in the art, and typically include a concrete form 12 that may be 900 feet long. The bed 10 has tracks 14 that ride on rails such that the entire bed 10 may be moved down the rails. This allows the bed 10 to be moved to each of the fixed stations, such as for pouring concrete on the bed from an overhead hopper.
The underside of a typical casting bed 10 is shown in FIGS. 2-4 in which it will be seen that a mechanism to precisely indicate the exact position on the bed 10 may be generated. The bed position device 20 is used to provide a signal that indicates the exact position of the bed to a known position in the plant. As shown, it involves the addition of a rack 22 to the underside of the casting bed 10. The rack 22 engages with a pinion 24 which is attached to an encoder 26. The rack 22 has a fixed rack anchor 28. The bed 10 includes a bed fixture bracket 30 which together with a linear decoder post 32 and a vemeer code readable scale 34 and linear encoded track monitor 36 is able to accurately gauge and report any differences in length of the bed due to tension of the prestressing cables or temperature changes. This allows variations in the casting bed 10 length to be accounted for due to seasonal temperature changes, and stress changes due to prestressing in the bed which over a very long casting bed 10 can be significant. The fixed encoder 26 is fed the bed length information and transmits the exact position on the bed as read by the rack 22.
FIGS. 1 and 2 show a finishing machine 60 over the bed that can apply rake finishes, brick imprints or any other surface patterning desired. FIG. 2 shows a surface finishing machine 60 situated over casting bed 10. It carries a lower fragmentary pattern unit 62 which may receive information from a control station 66 which may receive bed position information, any temperature compensation and information on the CAD drawing requirements and imprints the uncured concrete surface accordingly. Alternatively, the pattern unit may be manually operated or may simply receive position information without a tie-in to CAD drawings and a laser projection system. The lower pattern unit 62 is readily removable such that another unit with a different pattern may be attached. Thus, the bed may be imprinted exactly where needed, to the depth needed with whatever patterns are desired, from varying brick patterns to rake finishes and the like.
As best shown in FIGS. 4-8, the finishing machine 60 includes a frame 64, which in the case of a moving bed 10 positions the machine 60 over the bed without contact. A press assembly 66 carries the lower pattern unit 62 which may be readily swapped out with a different pattern. The press assembly 66 is raised and lowered by vertical actuators 70 which are controlled to imprint the pattern to the desired depth on the uncured concrete surface 72. The entire press assembly 66 may move lengthwise with relation to the bed 10 by virtue of tandem linear tracks 76 to which it is mounted by rollers 78. The side view of FIG. 6 shows that the press assembly 66 is able to move back and forth along the direction of the casting bed 10 by virtue of the tandem tracks 76 via linear actuators 80.
Distance measuring sensors 82 as shown in FIG. 6 may be advantageously employed to detect the distance between a fixed known position and the upper surface 72 of the concrete below the sensor. When the distance varies, it means that the thickness of the uncured concrete has varied slightly. With this information, the depth of the pattern may be kept constant by automatically adjusting the depth the lower patterning unit 62 descends to by the press assembly 66. Otherwise, the finished pattern could be too deep or too shallow and the aesthetics of the design could be less than optimal. The distance measuring sensors 82 may be the widely available laser emitters which are used to measure distance and which distance information can be fed to the machine in order to adjust the depth of the pattern as to concrete depth varies.
A control station 84 is connected to finishing machine 60 and bed positioning device 20. Thus, the information on the exact bed position relative to the finishing machine may be transmitted and the press assembly may be controlled accordingly.
The invention has been shown in the figures in connection with a moving casting bed. The invention is also usable in fixed bed casting, in which the bed is stationary but the various components used in making the concrete panels move about the bed. The laser would simply be on a track above and along the entire length of the bed. The bed positioning device would also be above the bed and relative to the moving components, such as the concrete hopper, etc. The finishing machine would then be mounted to be movable along the length of the casting bed.
While this invention may be embodied in many different forms, there are shown in the drawings and described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
Patent Application
20080069917
