AU678861B2

AU678861B2 - An improved combination counter rotating packerhead and vibrator assembly and method of operating thereof

Info

Publication number: AU678861B2
Application number: AU78970/94A
Authority: AU
Inventors: Thomas D. Grau
Original assignee: International Pipe Machinery Corp
Current assignee: International Pipe Machinery Corp
Priority date: 1992-11-23
Filing date: 1994-11-22
Publication date: 1997-06-12
Anticipated expiration: 2013-11-22
Also published as: AU688714B2; AU2009197A; TW302295B; AU7897094A

Description

VA twvovro~oe C bo«ViCon COeA r Raoru c6 er -6A A l \VIro16016 40ssemAL YA n gcA O0 Oeiocon Teo This invention relates generally to improvements in vibrators used for all the purposes for which vibrators are currently employed including compacting, densifying, feeding, conveying and homogenizing. More particularly, this invention relates to an annularly configured vibrator that transmits vibrations radially outward through an outer core and includes a passageway through the axial center of the vibrator. The configuration of the vibrator enables the vibrator to be disposed within a large piece of equipment such as a concrete pipe making machine, and further enables other functional elements of the equipment such as drive shafts, conduits or cables to be passed through the vibrator.

BACKGROUND OF THE INVENTION 1. Industrial vibrators have a wide variety of uses. Vibrators have been used in hoppers, bins and'railcars to keep granular materials flowing as they should. Vibrators have also been used in connection with structural and architectural concrete because vibration of wet concrete helps consolidate the concrete for a a0": stronger, more durable structure.

6 Q"L Although pneumatic vibrators are available in a variety of NT Ombodiments the general type of vibrators to which the present invention is concerned supplies air pressure through an inner, substantially cylindrical and solid shaft. Air passes through passageways in the shaft and engages a vane which directs the air substantially in one circumferential direction. The air, now proceeding in a substantially circular direction, engages an inner roller thereby causing the inner roller to rotate. The inner roller rotates in an eccentric orbit due to the presence of the vane which is disposed between the inner roller and the vibrator shaft. The inner roller is disposed within an outer roller and the rotating inner roller engages the outer roller thereby causing the outer roller to rotate eccentrically about the inner roller and shaft. The eccentric rotation of the inner and outer rollers about the shaft and within the vibrator body transmits vibrations radially outward through the outer roller and any structure associated therewith.

The primary drawback to this otherwise efficient design is the general configuration of the vibrator. The vibrator is cylindrical and disc shaped in configuration which limits use of the vibrator in multi-component equipment. For example, during the construction of concrete pipe or concrete cylinders in a concrete pipe making machine, it is-highly desirable to apply vibration to the just packed concrete. Further, it is highly W.: preferable to vibrate the concrete immediately after it is packed Swith either a longbottom cylinder, a packerhead or a combination of the two. To vibrate the concrete immediately after it is packed, the vibrator should be disposed immediately below the packerhead. However, this configuration is not possible with many current disc shaped vibrator designs because the drive shaft for the packerhead or longbottom must be disposed below the 2 packerhead or longbottom. Therefore, a cylindrical vibrator must be disposed below the drive shaft and drive mechanism of the packerhead or longbottom and, hence, substantially below the longbottom or packerhead.

By contrast, an annularly configured vibrator could be disposed immediately below the packerhead because the drive shafting of a counter rotating packerhead assembly could be passed through the center of the vibrator thereby enabling the vibrator to be disposed in close proximity to the packerhead.

Further, the drive shafting of a longbottom assembly could also be passed through the vibrator enabling the longbottom assembly to be disposed immediately above or below the vibrator, depending upon the design of the pipe making machinery.

Other applications of an annularly configured vibrator will be apparent to those skilled in the art. An annularly configured vibrator will have applications in the design of multi-component equipment or systems where the vibrator is but one component that must be disposed between or adjacent to other functional components. The primary benefit of such vibrators when used with other functional elements or parts of machinery or equipment is that the driving mechanism for the system can pass through the vibrator thereby providing greater flexibility to the designer of the equipment.

3 -4- Summary of the Invention It is an object of the present invention to provide an improved combination rotating packerhead and vibrating core assembly for a concrete pipe making machine and method of operation thereof.

There is disclosed herein an improved combination counter rotating packerhead and vibrating core assembly for a concrete pipe making machine, the assembly comprising: an upper concrete forming assembly for initially distributing dry cast concrete radially outward against a mold, the upper concrete forming assembly being rotatably 10 mounted to an upper drive means, the upper drive means rotating the upper concrete forming assembly in a first direction, a lower concrete forming assembly for secondary distribution of the dry cast concrete radially outward against the mold, the lower concrete forming assembly being 0'"0 rotatably mounted to a lower drive means, the lower drive means rotating the lower concrete forming assembly in a second direction, the second direction being opposite to the first direction, the upper drive means and the lower drive means including separate drive shafts, the drive shafts being coaxial, IN:\LIBII)00870:hrw a vibrator assembly located beneath the lower concrete forming assembly, an isolation section disposed between the vibrator assembly and the lower concrete forming assembly, the isolation section comprising a bearing mounted on rubber bushings, the bearing being connected to the vibrator assembly, and the rubber bushings being connected to the lower concrete forming assembly, the drive shafts extending through the isolation section and the vibrator assembly.

The forming assemblies are preferably upper and lower roller assemblies but it .:will be understood that a longbottom assembly may be substituted for either roller 1o assembly (or rollers) and still fall within the spirit and scope of the present invention.

The upper and lower concrete forming assemblies rotate in opposite directions to eliminate cage twist.

There is further disclosed herein an improved combination counter rotating packerhead and vibrating core assembly for a concrete pipe making machine, the is1 assembly comprising: an upper concrete forming assembly for initially distributing dry cast concrete radially outward against a mold, the upper concrete forming assembly being rotatably mounted to an upper drive means, the upper drive means rotating the upper concrete forming assembly in a first direction, [N:\LIBI110O870:hrw a lower concrete forming assembly for secondary distribution of the dry cast concrete radially outward against a mold, the lower concrete forming assembly being rotatably driven by a lower drive means, the lower drive meat; rotating the lower concrete forming assembly in a second direction, the second direction being opposite to the first direction, the upper drive means and the lower drive means including separate drive shafts, the drive shafts being coaxial, the lower concrete forming assembly being disposed above a core, the core having an upper end, the upper end of the core carrying a vibrator for vibrating the dry S0 10o cast concrete and carrying an isolation section for isolating the upper and lower concrete forming assemblies from the vibrator, the isolation section being disposed g i"...between the lower concrete forming assembly and the vibrator, the vibrator having an annular configuration, each drive shaft passing through V the vibrator.

15 There is still further disclosed herein a high speed method of making reinforced concrete pipe, the method comprising the steps of: traversing a combination counter rotating packerhead and vibrating core "assembly upward through a reinforcing wire cage located within a concrete pipe mold while dry cast concrete is being poured in to the concrete pipe mold, [N:\LIB100OO870;hrw applying a first radially outward force to the dry cast concrete while the packerhead and core assembly traverses through the cage, the first radially outward force being applied by rotating an upper concrete forming assembly of the packerhead and core assembly in a first direction to force the dry cast concrete into the reinforcing wire cage and against the concrete pipe mold, the upper concrete forming assembly being disposed at the upper end of the combination counter rotating packerhead and vibrating core assembly, applying a second radially outward force to the dry cast concrete while the packerhead and core assembly traverses through the cage, the second radially outward force being applied by rotating a lower concrete forming assembly of the packerhead and core assembly in a second directicn to further force the dry cast concrete into the i' reinforcing wire cage and against the concrete pipe mold, the second direction being opposite to the first direction so that any twist tended to be applied to the reinforcing cage imposed by rotating the upper concrete forming assembly in the first direction is 15 counteracted by rotating the lower concrete forming assembly in the second, opposite direction, the lower concrete forming assembly being disposed immediately below the upper concrete forming assembly, isolating the upper and lower concrete forming assemblies from vibrations imparted by a vibrator of he packerhead and core assembly with an isolation section of IN:\LIBO11100870:hrw the packerhead and core assembly disposed between the lower concrete forming assembly and the vibrator while the packerhead and core assembly traverses through the cage, vibrating the dry cast concrete with the vibrator and a core skin of the packerhead and core assembly while the packerhead and core assembly traverses through the cast, the vibrator being mounted on the core skin, the vibrator and core skin being disposed below and in juxtaposition to the lower concrete forming assembly, the first and second radially outward forces imparted by the upper and lower concrete forming assemblies being supplied by a drive means disposed through the vibrator.

10 Brief Description of the Drawings A preferred form of the present invention will now be described by way of Sexample with reference to the accompanying drawings, wherein: Figure 1 is a top plan view of a vibrator made in accordance with the present invention, particularly illustrating a plan view of the top plate; a IN:\LIBII100870:hrW Figure 2 is a section view taken substantially along line 2-2 of Figure 1; Figure 3 is a side plan view of the vane shown in Figure 2 but vertically rotated 1800 from its Figure 2 position; Figure 4 is an end view of the vane shown in Figure 3; Figure 5 is a bottom plan view of the vibrator shown in Figure 2 particularly illustrating the bottom plate thereof; Figure 6 is a partial section view taken substantially along line 6-6 of Figure Figure 7 is an elevation view of the vibrator shaft shown in Figure 2; Figure 8 is an end view of the vibrator shaft shown in Figure 7; Figure 9 is a section view taken substantially along line 9-9 of Figure 8; Figure 10 is a top plan view of the bearing used in connecting the top plate to the vibrator shaft shown in Figure 2; 9 Figure 11 is a section view taken substantially along line 11-11 of Figure Figure 12 is a bottom plan view of the top plate shown' in Figure 1; Figure 13 is a section view taken substantially along line 13-13 of Figure 12; Figure 14 is a bottom plan view of the bottom plate shown in Figure 2; Figure 15 is a section view taken substantially along line 15-15 of Figure 14; Figure 16 is a top plan view of the vibrator body shown in Figure 2; Figure 17 is a section view taken substantially along line 17-17 of Figure 16;

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Figure 18 is a plan view of the inner roller shown in S Figure 2; Figure 19 is a section view taken substantially along line 19-19 of Figure 18; 10 Figure 20 is a plan view of the outer roller shown in Figure 2; Figure 21 is a section view taken substantially along line 21-21 of Figure Figure 22 is a top plan view of a second embodiment of a vibrator made in accordance with the present invention; Figure 23 is a section view taken substantially along line 23-23 of Figure 22; Figure 24 is a side view of the vane illustrated in l0.' Figure 23 but vertically rotated 1800 from its Figure 23 position; l Figure 25 is an end view Lcf the vane shown in Figure 24; Figure 26 is a bottom plan view of the vibrator shown in Figure 23; 0 0 Figure 27 is an elevation view of the vibrator shaft shown Sin Figure 23; oo Figure 28 is an end view of the vibrator shaft shown in Figure 27; 11 Figure 29 is a section view taken substantially along line 29-29 of Figure 28; Figure 30 is a bottom plan view of the top plate shown in Figure 22;.

Figure 31 is a section view taken substantially along line 31-31 of Figure Figure 32 is a top plan view of the bottom plate shown in Figure 23; Figure 33 is a section view taken substantially along line 33-33 of Figure 32; sh Figure 34 is a vertical section view of the vibrator body S* shown in Figure 23; 0 Figure 35 is an end view of the inner roller shown in Figure 23; Figure 36 is a section view taken substantially along line 36-36 of Figure Figure 37 is an end view of the outer roller shown in Figure 23; 12 Figure 38 is a section view taken substantially along line 38-38 of Figure 37; Figures 39A through 39D illustrate the eccentrical orbit of the inner and outer rollers of the vibrators illustrated in Figures 2 and 23; Figures 40A through 40D illustrate the eccentrical orbit of an inner and outer roller of an alternative embodiment of the vibrator of the present invention.

Figure 41 is a perspective view of a concrete pipe making machine which includes a further embodiment of the vibrator; ~Figure 42 is a partial sectional view taken through the core of the concrete pipe making machine constructed in accordance with the present invention particularly showing the dual counter rotating packerhead and annular vibrator; Figure 43 is a top plan view of the unique vibrator assembly used in the embodiment of Figures 41-62 of the present invention; Figure 44 is a sectional view taken substantially along line 44-44 of Figure 43; Figure 45 is an elevational view of the vane used in the vibrator of the embodiment of Figures 41-62; 13 Figure 46 is an end view of the vane shown in Figure Figure 47 is a bottom view of the vibrator assembly shown in Figure 43; Figure 48 is a side elevational view of the vibrator shaft of the vibrator assembly of the embodiment of Figures 41-62; Figure 49 is a top end view of the vibrator shaft shown in Figure 48; Figure 50 is a sectional view taken substantially along line 50-50 of Figure 49; Figure 51 is a bottom view of the top plate of the vibrator shown in Figure 43; Figure 52 is a section taken substantially along line 52-52 of Figure 51; Figure 53 is a top view of the bottom plate of the vibrator assembly shown in Figure 43; Figure 54 is a sectional view taken substantially along line 54-54 of Figure 53; 14 Figure 55 is a sectional view of the vibrator body of the vibrator assembly shown in Figure 43; Figure 56 is an end view of the inner roller of the vibrator assembly shown in Figure 43; Figure 57 is a sectional view taken substantially along line 57-57 of Figure 56; Figure 58 is an end view of the outer roller of the vibrator assembly shown in Figure 43; Figure 59 is a sectional view taken substantially along line 59-59 of Figure 58; Figures 60A-60D are diagrammatic end view of the vibrator assembly illustrating the rotation of the inner and outer rollers; Figures 61A-61D are diagrammatic end views illustrating the motion of the inner and outer rings of a modified vibrator assembly; and Figure 62 is a partial sectional view showing a counter rotating packerhead with an upper roller head and lower longbottom assembly made in accordance with the present invention.

15 j DETAILED DESCRIPTION OF THE DRAWING Like reference numerals will be used to refer to like or similar parts from Figure to Figure in the following description of the drawings.

Turning first to Figure 1, a top plan view of a vibrator is illustrated, particularly illustrating the tope plate, indicated generally at 12, and the bearing, indicated generally at 14. Referring collectively to Figures 1 and 2, the cap screws indicated at 16 are used to affix the top plate 12 to the vibrator body indicated generally at 18. The cap screws 20 are used to attach the bearing 14 to the top plate 12 and then the cap screws shown at 22 are used to attach the top plate 12 and bearing 14 to the vibrator shaft indicated generally at 24.

Still referring to Figure 2, the bottom plate indicated generally at 26 is attached to the vibrator shaft 24 with the cap screws 28. The bottom plate 26 is then attached to the ring with the cap screws indicated at 32. The ring 30 is attached to the inside surface 34 of the vibrator body 18.

Still referring to Figure 2, the vibrator shaft 24 provides fluid communication between the port 36 which is in communication with the pressurized fluid supply (or pressurized air supply) and the annular space defined by the top plate 12, bottom plate 26, shaft 24 and body 18. Air enters the port 36 and proceeds up through the conduit or channel 38 in shaft 24. A plurality of 16 apertures 40 spaced along the channel 38 direct the air flow against the vane indicated generally at 42 which'reciprocates in slot 54, see Figure 8. As will be discussed below, the vane 42 directs the air flow against the inner roller, indicatea generally at 44, thereby causing it to rotate and engage the outer roller, indicated generally at 46, causing it to rotate.

The eccentric rotation of the inner roller 44 and outer roller 46 about the vane 42 and shaft 24 results in vibrational energy being transmitted outward through the vibrator body 18.

Turning to Figure 3, the vane 42 features a plurality of slots indicated generally at 48. Air proceeds through the apertures 40 (see Figure 2) and engages the slots before it is directed outward generally in the direction of the arrow (see Figure 4) where it engages the inside surface 52 (see also Figure 19) of the inner roller 44. The placement of the slots 48 along the vane 42 as shown in Figure 3 reflects the variances in the air pressure along the height of the conduit 38 (see Figure Specifically, as air enters through the port 36 and :o proceeds up through the conduit 38, the air pressure along the conduit 38 will vary. The spacing of the slots 48 along the vane 42 and the spacing of the apertures 40 along the conduit 38 reflect the variances in pressure along the height of the conduit 38 and are spaced to distribute the air pressure evenly against the inside surface 52 of the roller 44 to efficiently begin the rotation of the roller 44. The vane is received in the slot 54 disposed in the shaft 24 (see Figure Air is released from 17 the annular space that contains the rollers 44, 46 through the slots in the bottom plate 26 indicated at 56 (see Figures 2, and 14).

Turning to Figure 5, the bottom plate 26 is attached to the ring 30 via the cap screws 32 and the ring 30 is welded or otherwise attached to the inside surface 34 of the vibrator body 18. As noted above, the slots indicated generally at 56 release the air or pressurized fluid from the vibrator 10. The bottom plate 26 may also accommodate a proximity switch indicated generally at 58 which may shut the vibrator off in the event an object engages the undersurface 60 of the ring 30 or, as shown in Figure 6, if an object engages the probe 62 which extends downward from the proximity switch 58 through the ring *.ol .Turning now to Figures 7 through 9 collectively, the 0* vibrator shaft 24 includes the beveled extensions 64, 66 that are received in the top plate 12 and bottom plate 26 respectively.

The slot 54 receives the vane 42 and the apertures indicated at 40 direct pressurized fluid at the slots 48 of the vane 42 (see Figure The threaded holes 68 receive the cap screws 22 which attach the top plate 12 to the shaft 24. The holes 70 receive the cap screws 28 which attach the bottom plate 26 to the shaft 24.

TI- bearing 14 is illustrated in Figures 10 and 11. The holes 70 receive the cap screws 20 (see Figures 1 and 2) which 18

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I attach the bearing 14 to the top plate 12. The slot 72 .receives the head and washer of the cap screws 22 (see also Figures 1 and 2) which attach the top plate 12 to the vibrator shaft 24.

Turning to Figures 12 and 13, the holes 74 of the top plate 12 receive the cap screws 16 that attach the top plate 12 to the upper end of the vibrator body 18. The holes 76 receive the cap screws 22 that attach the top plate 12 to the vibrator shaft 24.

The holes indicated at 78 receive the cap screws 20 that attach the bearing 14 to the top plate 12. The top plate 12 also includes a plurality of slots or channels 80 that increase the turbulence of the air or fluid flow in the annular space defined by the shaft 24, top plate 12, bottom plate 26 and body 18. As seen in Figure 13, the slots 80 do not pass through the top plate 12. In contrast, the slots 56 disposed in the bottom plate 26 (see Figure 14) pass through the bottom plate 26 and not only increase the turbulence of the air flow in the annual space but also act to release air or fluid pressure from the vibrator Returning to Figure 13, the beveled upper end 64 of the shaft 24 is accommodated in the recess 81 of the top plate.

'0 o Similarly, the beveled lower end 66 of the shaft 24 is accommodated in the recess 82 disposed in the bottom plate as shown in Figure 15. Referring to Figures 14 and 15, the bottom plate includes a plurality of holes 84 to accommodate the cap screws 32 which attach the bottom plate to the ring 30 (see Figure The bottom plate also includes the plurality of holes- 19 indicated generally at 86 that accommodate the cap screws 28 which attach the bottom plate 26 to the vibrator shaft 24.

The vibrator body is illustrated in Figures 16 and 17. The ring 30 is welded or otherwise fixedly attached to the inside surface 34 of the vibrator body 18. Accordingly, the vibrator bottom plate is inserted down through the upper end 88 of the vibrator body 18 before it is accommodated in the recess 90. The holes indicated at 92 accommodate the cap screws 16 as shown in Figure 2. The holes indicated at 94 accommodate the cap screws 32 which fixedly attach the bottom plate 26 to the ring 30. The recess 96 disposed in the ring 30 is in alignment with the airrelease apertures or slots 56 disposed in the bottom plate 26.

The hole 98 disposed in the ring 30 accommodates a downwardly o extending probe 62 of a proximity sensor 58 (see Figure 6).

LS. The inner roller 44 and outer roller 46 are illustrated in Figures 18 through 21. As seen in Figures 18 and 20, the inner roller 44 is thinner and less bulky-than the outer roller 46.

Accordingly, in operation, air or pressurized fluid engages the inside surface 52 of the inner roller 44 and the inner roller 44 20 starts to rotate. Then, the outside surface 102 of the inner roller engages the inside surface 104 of the outer roller 46.

Because the movement of the inner roller 44 is initiated by .i pressurized air or fluid, it is preferable to employ a relatively light inner roller 44 which, in turn, initiates the movement of the heavier outer roller 46.

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Turning now to Figures 39A through 39D, the rotation of the rollers 44, 46 is illustrated. Referring first to Figure 39A, the outside edge 103 of the vane 42 engages the inside surface 52 of the inner roller 44. Air engages the slots 48 in the vane 42 and is thereafter directed in the counterclockwise direction as shown in Figure 39A. Turning to Figure 39B, the air pressure coming off of vane 42 causes the inner roller 44 to rotate in the counterclockwise direction as shown by the gap between the inner surface 52 of the inner roller 44 and the outside surface of the vibrator shaft shown at 100. As seen in Figures 39C and 39D, the inner roller 44 continues to rotate about the outside surface 100 of the shaft 24 and the vane 42 oscillates from the fully extended position as shown in Figure 39A to a collapsed position as shown in Figure 39C. The engagement between the outside surface 102 of the inner roller 44 and the inside surface 104 of the outer roller 46 causes the outer roller 46 to rotate in the counterclockwise direction. The engagement between the outer edge 103 of the vane 42 and the inner surface 52 of the inner roller 44 causes the inner roller 44 to rotate in an eccentric z fashion. In other words, the inner roller 44 does not rotate about a single axis due to the engagement between the inner S roller 44 atd the oscillating vane 42. Consequently, the outer roller 46 also rotates in an eccentric fashion. The irregular or eccentric rotations of the inner roller 44 and outer roller 46 cause intense vibrations which are transmitted outward through the vibrator body 18. A similar oscillation is illustrated with 21 respect to smaller rollers and an alternative embodiment 4n Figures 40A through Turning now to Figures 22 through 38, an alternative embodiment is illustrated. The vibrator shown in Figures 22 through 39 is somewhat functionally similar to the vibrator shown in Figures 1 through 21 and similar parts are identified with the same reference number with the prefix the top plate "212" as opposed to the top plate 12). In the embodiment of Figures 22 through 38, the vibrator 210 is consistently larger, and the bottom plate 226 is attached directly to the vibrator body 218 as opposed to the ring 30 as shown in Figure 2.

Further, the vibrator body 218 is equipped with an outer ring 219 as shown in Figure 22 which is used to mount the vibrator 210 inside a core 221. The core 221 includes a ring 223. The core :16" 221, in the example shown in Figure 23, may be used in the S fabrication of concrete pipe. The remaining functional elements of the vibrator 210 are similar or analogous to the functional elements described above with respect to the vibrator 10 shown in Figures 1 through 21.

One of the primary benefits provided by the annular too*.: configuration of the vibrators 10 and 210 is that functional parts such as drive shafts, cables or conduits can be passed through the vibrator which makes the vibrators 10 and 210 more useful as one component of a multi-component s: stem. In other words, the designer of a multi-component system has great.-..

22 q_ flexibility in the design of the system because an entire section of the system need not be reserved for the pneumatic vibrator.

The vibrator can be spaced closely between two other components and the functional elements such as drive shafts, conduits, cables, etc. of adjacent components can be passed directly through the vibrator.

This invention also relates to improve: nts in concrete pipe fabrication. More particularly, this invention relates to an improved combination packerhead and vibrating core assembly in a concrete pipe making machine and a high speed method of forminconcrete pipe. The invention thus provides the benefits of a counterrotating packerhead with a vibrating core in one fast and economical system.

Counter rotating packerheads for concrete pipe making machines are known in the art. Counter rotating pac)krheads with a vibrator disposed below the packerhead are also known in the art. However, no design taught by the prior art effectively C,.t combines the benefits provided by counter rotating packerhead e C.

technology with vibrator technology to provide a concrete pipe making machine that produces high quality pipe at high production rates.

The problem primarily associated with counter rotating packerheads is low pipe density. Attempts to cure this defect 23 -b resulted in the first combination counter rotating packerheads/ vibrator concrete pipe making machines.

Concrete pipe making methods that employ vibrators only are subject to slumping problems unless carefully contracted. The voids and other distortions (also referred to as concreteslumping) are primarily caused by the volume reduction of the concrete after the vibration. Vibration causes dry cast concrete to densify which results in a reduction in volume. The reduction in volume will result in void spaces around the form work, especially at or near the wire reinforcing cages.

In rising core concrete pipe making machines, the density levels attainable in the pipe are limited. If the vibrational frequency is increased to too high a level, concrete-slumping, void spaces and other distortions will be present in the finished pipe. This is especially problematic in irregularly shaped pipes o.

such as pipes with top spigots, tongue joints and grooved gasket joints.' Unsatisfactory pre-packing, before vibration will cause concrete-slumping, especially in forms used to make the abovenoted irregularly shaped pipes. Pre-packing using weighted &200 forming rings has been tried but manufacturers then encounter problems with length control. If the pipe lengths and joints do not meet specifications, the pipes will be rejected.

Another problem associated with current concrete pipe making machines is attributable to the hydraulic vibrators which, to 24 this point in time, have been the preferred type of vibrator.

Because of the size of hydraulic vibrators generally, the vibrator must be disposed substantially below the lower roller assembly of the counter rotating packerhead. This placement further compromises the potential effectiveness of the general concept of combining a counter rotating packerhead with a vibrator. Ideally, strong vibrating forces should vibrate the concrete immediately after or concurrently with the application of the radially outward forming forces exerted by the counter rotating packerhead. By combining the action of the counter rotating packerhead with an immediate vibrating action, the entire pipe making process could be shortened. However, when the actions of the counter rotating packerhead and the vibrator are separate and distinct from one another due to the inherent structure of the hydraulic vibrator, the pipe making process is unduly prolonged.

Thus, there is a need for an improved system in which a core vibrator may be disposed immediately below a counterrotating packerhead thereby providing a truly combined counter rotating packerhead/vibrator assembly, yet providing improved isolation Sfrom the working parts of the packerhead to a far greater degree than is presently provided. There is also a need for an improved drive shaft/drive system for a counter rotating packerhead that enables the drive means to be disposed in a remote location and isolated from the vibrator.

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Still another problem associated with the prior art is the general lack of attempts to increase the rate of pipe making construction. The present invention contributes to this need in the art by providing a counter rotating packerhead assembly where the vibrator and counter rotating packerhead are disposed adjacent to one another for faster and hence more economical pipe making production.

The present invention also discloses a pipe making machine with multiple cores and multiple forms so the machine makes at least two pipes of equal or different sizes at once, thereby increasing pipe productivity.

Referring now to Figure 41, a concrete pipe making machine is indicated generally at 310. The machine includes dual feed conveyors 311, 312, dual pipe molds 313, 314 and dual cores 315, 316. After two pipes are fabricated in molds 313, 314, the turntab'e' 317 is rotated 90, 180 or 270 degrees so that two additional molds 318, 319 are placed under the platform 322 and the process is begun again. The entire process is automated and controlled via the automation control panel 323.

Initially, concrete contained in the hoppers 324,. 325 flows down through the conveyors 311, 312, and then through the holes 326, 327 in platform 322 into the molds 313, 314. The cores 315, 316 are mounted on a horizontal lift platform as indicated generally at 328 and the horizontal lift platform 328 is raised 26 I upward as the cores 3i5, 316 traverse through the molds 313, 314.

The upper surface 331 of the lift platform 328 engages the underside (not shown) of the turntable 317 after the pipes have been fabricated inside the molds 313, 314. Hydraulic cylinders 329, 332 raise and lower the horizontal lift platform 328. The hydraulic cylinders 329, 332 are attached to right frame member 333. Left frame member 335 serves as an axis for rotation of the turntable 317, the axis being co-axial vith the axis of the central hole 334 of turntable 317.

Turning to Figure 42, the action of a combination counter rotating packerhead and vibrator assembly is indicated generally at 340. The assembly is illustrated inside a mold, indicated at 313. Concrete 341 is supplied downward from a conveyor, such as •go* 311 (see Figure 41). The mold 313 is equipped with a reinforcing cage 342.

As concrete 341 is deposited on top of the assembly 340 it is pushed circumferentially outwardly by upwardly protruding paddles or fins, shown at 343. At least two fins 343 are mounted to the upper plate 344 of each upper roller 345 in upper roller assembly 336. Each upper roller 345 is rotatably mounted to the base plate 346 by a bolt 347. The base plate 346 is fixedly attached to the inner drive shaft 348 by the head nut 363. The upper base plate 346 is locked to the inner drive shaft 348 by a hub 362 having an integral key 360 which meshes with the spline 361 on the upper end of shaft 348.

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The inner drive shaft is turned in the direction of the arrow 352 by a drive means or motor located beneath 'the lift platform 328 (not shown). As will be noted below, the outer drive shaft 349 is rotated in the direction of the arrow 353, which is in a direction opposite to the inner drive shaft 348, by a drive means located beneath lift platform 328 (see Figure 41) to provide the counter rotating action.

The lower roller assembly, indicated generally at 337, includes rollers 354 which are rotatably attached to a base plate 355 by bolts 356. The base plate 355 is connected to the outer drive shaft 349 by attachment to the circular sleeve 357 which is in turn welded to the upper end of outer drive shaft 349. The base plate 355 is mounted to the sleeve 357 by bolt 358.

The upper roller assembly, indicated generally at 336, *i.t includes the upper rollers 345 and the lower rollers 354 which are all mounted to the posts or bolts 347, 356 respectively with a plurality of bearings, shown generally at 364. Each base plate 346, 355 is equipped with an outer abrasion resistant member, shown generally at 359.

eoeoe: Another aspect of the invention resides in the isolation of the roller assemblies 336 and 337 from the vibrator 365. This is primarily accomplished by the isolation section 368 that includes a bearing 366 mounted on rubber bushings 367 to mechanically isolate the roller assemblies 336, 337 from the vibrator 365. As 28

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_1_ best seen in Figure 42, it will be noted that the vibrator 365, despite being isolated from the lower rollers 354, is still disposed essentially immediately below the lower rollers 354.

The vibrator 365 consists of an annular top plate 372 and an annular bottom plate 373 which are connected one to the other by an annular vibrator body 374, see also Figure 55, at the outer peripheries of the top plate 372 and bottom plate 373 via a plurality of bolts, shown generally at 376. Further, the annular top plate 372 and the annular bottom plate 373 are connected at the inner peripheries thereof by a vibrator shaft 375, see also Figure 50, and the bolts 377. The annular space bound by the top plate 372, the bottom plate 373, the body 374 and the shaft 375 contains a vane, indicated generally at 378 (see Figures 44-47),

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an inner roller and an outer roller 382.

V 5K" The vibrator 365 shown in Figure 42 is a pneumatic vibrator that is riven by air or another suitable fluid supplied through the hose 383 which is connected to a pressurized fluid supply o (not shown). Air enters through the hose 383, through the conduit 384 in shaft 375, and through the small drilled holes 385 in the vibrator shaft 375. After passing through the small drilled holes 385, the air engages the vane 378 which in turn drives the inner roller 379 and the outer roller 382 in a rotating fashion indicated by the arrow 386. Durable O-rings or other sealing means 380 may be disposed in the grooves 380a disposed in the upper and lower ends of the inner roller 379 to 29 I inhibit the leakage of air as air and the vane 378 engage the inner roller 379. The O-ring 380, quad-ring 380 or'other sealing means 380 should be comprised of a durable material such as a phenolic resin or other suitable gasket material that is durable.

The rotation indicated at 386 imparts vibration to the vibrator body 374 which is imparted to the core skin 387 through the brackets shown generally at 388. The upper half-bracket 388a is mounted to the vibrator body 374 while the lower half-bracket 388b is mounted to the inside of the core skin 387. The upper and lower bracket halves are connected by a plurality of bolts 389. It will be emphasized that the vibrator 365 is mechanically isolated from the upper and lower roller assemblies 366, 377 (or the upper and lower concrete forming assemblies 336, 337).

Thus, the combination counter rotating packerhead and vibrator assembly 340 first applies radially outward, upward and *."downward forces on the concrete 341 by the action of the upper rollers 345 (or upper concrete forming assembly 336) as indicated by arrows 336a, 336b, 336c respectively as the upper rollers 345 rotate in the direction of the arrow 352. The action of the 20. upper rollers 345 pushes the concrete 341 through the cage 342 and against the mold 313. The cage 324 is simultaneously urged or twisted in the direction of arrow 352 due to the mass, ge e S: velocity and direction of movement of the concrete. Immediately thereafter, and as the assembly 340 proceeds upwardly, the lower rollers 354 (or lower concrete forming assembly 337) impart additional radially outward, upward or downward forces on 30

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the concrete 341 as indicated by arrows 337a, 337b and 337c respectively further pressing it through the cage 342 and against the mold 313. The mass, velocity and direction of movement of the concrete exerts s twisting force on the cage in the diiection of the arrow 353 which substantially or entirely counteracts the twist imparted to the cage by the upper roller assembly 336 as indicated by the arrow 352. The downward forces 336c of the upper rollers 345 counteract the upward forces 337b of the lower rollers 354 thereby effectively pre-packing the concrete prior to vibration. As the assembly 340 proceeds upward, the concrete 341 in general and especially the concrete being pushed in the direction of arrow 337c is contemporaneously and immediately subjected to vibrations from the vibrator 365 through the core skin 387.

It will be noted that an important benefit of the present invention is the location of the vibrator 365 almost directly beneath the lower rollers 354 so as to impart vibratory forces to the dry cast concrete 341 immediately after it has been displaced a radially outward through the cage 342 and against the mold 313 by the upper rollers 345 and lower rollers 354. This preferred arrangement is accomplished by providing a vibrator that is driven by a motive fluid which requires a space only sufficient s* to accommodate a motive fluid power supply conduit. As seen in Figures 42 and 43, the solid and hollow drive shafts 348, 349 pass through the annulus of the vibrator 365.

31 i -r Figures 44-47 illustrate the construction and operation of the vibrator 365 in greater detail. The top plate 372, the bottom plate 373, the body 374 (see also Figure 55) and the shaft 375 (see also Figure 50) define an annular area that contains the vane 378, the inner roller 379 and the outer roller 382. Air enters from the air hose 383 (shown in Figure 42), through the inlet 384a into the conduit 384 drilled within the wall of the shaft 375. Air then passes through the small drilled holes, shown generally at 385, and engages the vane 378. The action of the air against the vane 378 causes rotation of the inner roller 379 and outer roller 382 in a circular fashion indicated by the arrow 386 shown in Figure 42. Since half-bracket 388a connects the vibrator 365 to the core 387 (see Figure 42) the vibratory impulses generated by vibrator 365 are imparted to the freshly pre-packed concrete disposed between the mold 313 and the core skin 387.

Figures 45 and 46 are detailed illustrations of the vane 378. The vane 378 is preferably made of phenolic bonded canvas with a series of slots 390 dispsed therein. Air enters through the entrance 390a of the slots and causes the vane 378 to engage the inner roller 379 (not shown in Figure 45i; see Figure 44).

Figure 46 is an illustration of the relative thickness of the

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vane 378 and the slots 390.

Figure 48 is a side view of the vibrator shaft 375. The small drilled holes 385 allow for the pressurized fluid to pass 32

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through and engage the vane 378 (see Figure 44). The shoulder 381 of the shaft 375 engages the inside corners of extensions 396 of the top plate 372 and the bottom plate 373 (see Figures 44, 52 and 54). As seen in Figure 49, the vibrator shaft 375 includes a series of bolt holes 392 for attachment to the top plate 372 and the bottom plate 373. As seen in Figure 50, the conduit 384 allows pressurized fluid from the pressurized fluid reservoir (not shown to enter the shaft body '75 and pass through the small drilled holes 385 to engage the vane 378.

From Figures 51 and 52 it will be noted that the slots 393 allow for the escape of pressurized fluid that enters the vibrator 355 from the pressurized fluid reservoir.

Figures 56 and 57 illustrate the inner ring 379, sealing means 380 and groove 390. Figures 58 and 59 illustrate the outer ring 382. The vibrational action of the vibrator 365, and specifically the action of the rings 377 and 382, is best understood upon viewing Figures 60A through 60D. Air enters through the small drilled holes 385 and engages the 1vane 378, driving it outwardly until the left end of the vane 378, as viewed in Figure 45, engages the inner peripheries of inner ring 379. The inner ring 379 pushes against the outer ring 282, and, because the vane slots 390 are closed on one side, the vane causes the inner, and then the outer, rings to roll around the internal surface 397 of body 374. Figures 61A through 61D 33 I lslPT illustrate this circular vibrating motion in a vibrator having smaller inner ring 379a and outer ring 382a.

Figure 62 is an illustration of an alternative embodiment.

The counter rotating packerhead assembly, indicated generally at 440, includes an upper-set of rollers indicated generally at 445 and a lower longbottom assembly indicated generally at 454 in lieu of a lower set of rollers 354 (compare with Figure 42). The longbottom assembly 454 is mounted to the longbottom support plate 455 which in turn is connected to the outer drive shaft by bolts 458. The wear resistant segments 459 can be replaced upon removing the screw 462 and nut 462a. Abrasion resistant wear bands 459a help prevent dry cast concrete from entering the inner workings of the counter rotating packerhead 440. The vibrating core shown at 487 is analogous to that shown at 387 in Figure 42.

SThus, an improved packerhead and vibrator assembly is provided for improved quality pipe which can be made at a rate much faster than the rate at which vibrated pipe is currently made. The unique annular vibrator allows the vibrator to be disposed closer to the packerhead than known heretofore. The Q: drive means for the assembly is now disposed safety below the vibrator and is protected from the vibrations imparted to the S core by the vibrator. The disclosed design is mechanically more reliable and produces quality pipe easter than designs previously available.

34 I 1-~1 Although several embodiments of the present invention have been illustrated and described, it will at once be apparent to those skilled in the art that variations may be made within the spirit and scope of the invention. Accordingly, it is intended tlat the scope of the invention be limited solely by the scope of the hereafter appended claims and not by any specific wording in the foregoing description.

*ee 0 «o oto. 0 0* 001.

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Claims

1. An improved combination counter rotating packerhead and vibrating core assembly for a concrete pipe making machine, the assembly comprising: an upper concrete forming assembly for initially distributing dry cast concrete radially outward against a mold, the upper concrete forming assembly being rotatably mounted to an upper drive means, the upper drive means rotating the upper concrete forming assembly in a first direcicn, a lower concrete forming assembly for secondary distribution of the dry cast concrete radially outward against the mold, the lower concrete forming assembly being rotatably mounted to a lower drive means, the lower drive means rotating the lower concrete forming assembly in a second direction, the second direction being opposite to the first direction, :0. to the upper drive means and the lower drive means including separate drive shafts, the drive shafts being coaxial, S: 15 a vibrator assembly located beneath the lower concrete forming assembly, an isolation section disposed between the vibrator assembly and the lower concrete forming assembly, the isolation section comprising a bearing mounted jn rubber bushings, the bearing being connected to the vibrator assembly, and the rubber bushings being connected to tdie lower concrete forming assembly, 20o the drive shafts extending through the isolation section and the vibrator assembly.

2. The assembly of claim 1, wherein the upper and lower concrete o forming assemblies are roller assemblies.

3. The assembly of claim 1, wherein the upper concrete forming assembly is a roller assembly and the lower concrete forming assembly is a longbottom assembly.

4. The assembly of claim 1, further including a means for supplying power to the upper and lower drive means, the means for supplying power to the upper and lower drive means being disposed below the vibrator.

5. An improved combination counter rotating packerhead and vibrating core assembly for a concrete pipe making machine, the assembly comprising: an upper concrete forming assembly for initially distributing dry cast concrete radially outward against a mold, the upper concrete forming assembly being rotatably mounted to an upper drive means, the upper drive means rotating the upper concrete forming assembly in a first direction, a lower concrete forming assembly for secondary distribution of the dry cast concrete radially outward against a mold, the lower concrete forming assembly being ~rotatably driven by a lower drive means, the lower drive means rotating the lower N:\LIBIIIOO870:hrw L- II III -37- *s o 0* 0 C. *0 0* *O .C 0 C. C concrete forming assembly in a second direction, the second direction being opposite to the first direction, the upper drive means -'nd the lower drive means including separate drive shafts, the drive shafts being coaxial, the lower concrete forming assembly being disposed above a core, the core having an upper end, the upper end of the core carrying a vibrator for vibrating the dr; cast concrete and carrying an isolation section for isolating the upper and lower concrete forming assemblies from the vibrator, the isolation section being disposed between the lower concrete forming assembly and the vibrator, the vibrator having an annular configuration, each drive shaft passing through the vibrator.

6. The assembly of claim 5, further including means for supplying power to the upper and lower drive means, the means for supplying power to the upper and lower drive means being disposed below the vibrator. 15

7. The assembly of claim 5, wherein the isolation section includes bearing means mounted on rubber bushings to isolate the lower concrete forming assembly from the vibrator, the bearing means being connected to the vibrator, and the rubber bushings being connected to the lower concrete forming assembly.

8. A high speed method of making reinforced concrete pipe, the method 20 comprising the steps of: traversing a combination counter rotating packerhead and vibrating core assembly upward through a reinforcing wire cage located within a concrete pipe mold while dry cast concrete is being poured in to the concrete pipe mold, applying a first radially outward force to the dry cast concrete while the packerhead and core assembly traverses through the cage, the first radially outward force being applied by rotating an upper concrete forming assembly of the packerhead and core assembly in a first direction to force the dry cast concrete into the reinforcing wire .age and against the concrete pipe mold, the upper concrete forming assembly being disposed at the upper end of the combination counter rotatin, packerhead and vibrating core assembly, applying a second radially outward force to the dry cast concrete while the packerhead and core assembly traverses through the cage, the second radially outward force being applied by rotating a lower concrete forming assembly of the packerhead and core assembly in a second direction to further force the dry cast concrete into the reinforcing wire cage and against the concrete pipe mold, the second direction being opposite to the first direction so that any twist tended to be applied to the reinforcing cage imposed by rotating the upper concrete forming assembly in the first direction is counteracted by rotating the lower concrete forming assembly in the second, opposite [N:\LIBII100870:hrw l I -38- direction, the lower concrete forming assembly being disposed immediately below the upper concrete forming assembly, isolating the upper and lower concrete forming assemblies from vibrations imparted by a vibrator of the packerhead and core assembly with an isolation section of the packerhead and core assembly disposed between the lower concrete forming assembly and the vibrator whlew the packerhead and core assembly traverses through the cage, vibrating the dry cast concrete with the vibrator and a core skin of the packerhead and core assembly while the packerhead and core assembly traverses through the cast, the vibrator being mounted on the core skin, the vibrator and core skin being disposed below and in juxtaposition to the lower concrete forming assembly, the first and second radially outward forces imparted by the upper and lower concrete i forming assemblies being supplied by a drive means disposed through the vibrator.

9. An improved combination counter rotating packerhead and vibrating core assembly for a concrete pipe making machine substantially as described herein with reference to the accompanying drawings. A high speed method of making reinforced concrete pipe substantially as hereinbefore described with reference to the accompanying drawings. Dated 8 April, 1997 International Pipe Machinery Corp. Patent Attorneys for the Applicant/Nominated Person SPRUSON 8 FERGUSON [N:\LIBO]00B70:hrw ABSTRACT IMPROVEMENTS IN VIBRATORS AND MACHINES EQUIPPED THEREWITH An improved pneumatic vibrator (365) and a concrete pipe making machine (310) utilizing said vibrator is provided. The vibrator (365) is annular in configuration which enables functional elements of adjacent components in a multi-component system to be passed through the vibrator. The configuration of the annular vibrator of the present invention conserves space in multi-component manufacturing systems. In a concrete pipe making machine (310), a counter rotating packerhead comprising counter to rotating assemblies (336, 337), longbottom assemblies or a combination thereof is disposed directly over an annular pneumatic vibrator (365). The coaxial drive shaft (348) for the counter rotating packerhead passes through the vibrator thereby permitting the power transmission means to be located below, and isolated from, the vibrator (365). The vibrator (365) is disposed below, but adjacent to, the counter rotating packerhead for faster pipe production. (Fig. 42) 0* IN:\LIDD)0063:RLF