WO2004067242A1 - Method and apparatus for resurfacing concrete blocks - Google Patents

Method and apparatus for resurfacing concrete blocks Download PDF

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Publication number
WO2004067242A1
WO2004067242A1 PCT/CA2004/000104 CA2004000104W WO2004067242A1 WO 2004067242 A1 WO2004067242 A1 WO 2004067242A1 CA 2004000104 W CA2004000104 W CA 2004000104W WO 2004067242 A1 WO2004067242 A1 WO 2004067242A1
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WO
WIPO (PCT)
Prior art keywords
drum
drums
loading
concrete blocks
unloading
Prior art date
Application number
PCT/CA2004/000104
Other languages
French (fr)
Inventor
Wallace Grubb
Original Assignee
Grubb-Amc Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Grubb-Amc Inc. filed Critical Grubb-Amc Inc.
Publication of WO2004067242A1 publication Critical patent/WO2004067242A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28D—WORKING STONE OR STONE-LIKE MATERIALS
    • B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
    • B28D1/006—Artificial ageing of stones; Providing stones with an antique appearance
    • B28D1/008—Artificial ageing of stones; Providing stones with an antique appearance by means of a tumbler

Definitions

  • the present invention relates to methods and systems for resurfacing concrete blocks, and more particularly to a method and system for handling and tumbling concrete blocks so as to provide them with an antique appearance.
  • Concrete blocks resurfacing machines are used to provide a so-called antique look to concrete blocks, by artificially wearing and chipping the visible outer surfaces of the concrete blocks so as to provide them with a similar rough appearance than that of wild, naturally developed stone blocks.
  • the artificial wearing of concrete blocks can be done by tumbling the blocks in a large hollow rotating drum wherein a number of blocks are inserted. As the drum rotates, the blocks will collide within the drum, thus damaging one another and wearing their outer surfaces to provide the desired antique appearance.
  • a problem with these rudimentary tumbling apparatuses is that the concrete blocks are often damaged to an extent that they cannot be used for their intended structural purpose anymore. Moreover, these tumbling apparatuses lack automation as they cannot be used in cooperation with block handling equipment.
  • the present invention relates to a block resurfacing system comprising a tumbling apparatus and a loading device, said tumbling apparatus comprising:
  • - first drive means capable of selectively rotating said carousel about said carousel rotation axis in order to selectively move each said planetary drum between a drum- loading position and a drum-unloading position;
  • each said - second drive means capable of selectively rotating each said planetary drum about said corresponding drum rotation axis; wherein said loading device can be selectively activated for loading concrete blocks in each said drum positioned in said drum-loading position, wherein each said drum can be unloaded when it is positioned in said drum-unloading position, and wherein said second drive means can be activated for tumbling and consequently resurfacing concrete blocks located in said drums.
  • said block resurfacing system further comprises drum- unloading means for unloading concrete blocks from each said drum positioned in said drum-unloading position.
  • said frame comprises an upright stationary front wall installed adjacent said carousel, each said drum positioned in said drum-loading position registers with a loading opening made in said front wall, and each said drum positioned in said drum-unloading position registers with a drum-unloading opening made in said front wall.
  • all of said drum rotation axes and said carousel rotation axis are mutually parallel and substantially horizontal.
  • said unloading means comprises a frustoconical shape of each said drum, each said drum thus defining a diametrically smaller end and a diametrically broader end, and said frustoconical shape of each said drum is destined to allow concrete blocks located in each said drum to be continuously gravity-biased towards said diametrically broader end of each said drum.
  • said diametrically broader end of each said drum is open, and said diametrically broader end of each said drum positioned in said drum- unloading position is juxtaposed to said housing unloading opening, for allowing concrete blocks to be unloaded from each said drum positioned in said drum-unloading position by passing through said diametrically broader open end of said drum, through said housing unloading opening and thus out of said tumbling apparatus.
  • said loading device is a block-pushing mechanism.
  • the present invention also relates to a block resurfacing system comprising a feed conveyor for conveying concrete blocks towards a first tumbling apparatus and an outlet conveyor for conveying concrete blocks away from said first tumbling apparatus, and further comprising a loading device, said first tumbling apparatus comprising:
  • said feed conveyor can be activated for conveying concrete blocks to said first tumbling apparatus and for engaging them in said loading device, wherein said loading device can be selectively activated for loading concrete blocks in each said drum positioned in said drum-loading position, wherein each said drum can be unloaded when it is positioned in said drum-unloading position, wherein said second drive means can be activated for tumbling concrete blocks located in each said drum, and wherein said outlet conveyor can be activated for conveying concrete blocks away from said first tumbling apparatus after having been unloaded from said set of planetary drums.
  • said block resurfacing system further comprises a second tumbling apparatus comprising:
  • each said drum of said second set of planetary drums can be loaded when it is in said second drum-loading position, wherein each said drum of said second set of planetary drums can be unloaded when it is positioned in said second drum-unloading position, and wherein said fourth drive means can be activated for tumbling and consequently resurfacing concrete blocks located in said drums of said second set of planetary drums.
  • said feed conveyor is common to both said first and said second tumbling apparatuses.
  • said loading device is common to both said first and said second tumbling apparatuses.
  • the present invention also relates to a method for handling concrete blocks and for tumbling the concrete blocks in a tumbling apparatus, said tumbling apparatus comprising a carousel rotatably mounted to a frame, a number of planetary drums each rotatably mounted to said carousel, said tumbling apparatus being located adjacent a loading device for loading concrete blocks in said planetary drums, said method comprising the steps of: rotating said carousel in order to successively index said drums at a drum-loading position; loading concrete blocks in each said drum when it is indexed at said drum-loading position; revolving said drums to tumble, and thus resurface the concrete blocks located therein; - rotating said carousel in order to index said drums successively at a drum-unloading position; and unloading blocks from each said drum when it is indexed at said drum-unloading position.
  • said drums revolve continuously.
  • said blocks are unloaded from said drums by being expelled therefrom due to the drums being frustoconical in shape, horizontally disposed and rotated about a horizontal axis, the drums having a larger front mouth opening for loading and unloading purposes.
  • the present invention more generally relates to a block resurfacing system for resurfacing concrete blocks, comprising: a feed conveyor defining a downstream end towards which the blocks are destined to be conveyed; a frame; a tumbling apparatus comprising a number of rotatable drums mounted to said frame and destined to tumble concrete blocks for resurfacing the concrete blocks; a loading device adjacent said feed conveyor downstream end, for loading concrete blocks from said feed conveyor into said drums; indexing means capable of selectively adjusting the relative position of said loading device and said drums for loading concrete blocks in selected ones of said drums according to a predetermined loading sequence; and unloading means cooperating with said drums for unloading said drums according to a predetermined unloading sequence.
  • said loading device comprises a pushing member movable along a bench
  • said indexing means and said loading device include a pushing member actuator capable of moving said pushing member between a first position adjacent a first drum and a second position adjacent a second drum, whereby said pushing member is destined to load concrete blocks located on said bench in said first drum when said pushing member is moved from said second position towards said first position, and in said second drum when said pushing member is moved from said first position towards said second position.
  • said indexing means comprises a first carousel rotatably mounted to said frame and rotatably carrying a number of said drums, said first carrousel being discretely rotated to allow said drums to be loaded by said loading device according ⁇ to said predetermined loading sequence, and said first carrousel further being discretely rotated to allow said drums to be unloaded by said unloading means according to said predetermined unloading sequence.
  • said indexing means further comprises a ' second carousel rotatably mounted to said frame and rotatably carrying a number of additional said drums, said second carrousel being discretely rotated to allow said additional drums to be loaded by said loading device according to said predetermined loading sequence, and said second carrousel further being discretely rotated to allow said additional drums to be unloaded by said unloading means according to said predetermined unloading sequence.
  • said loading device comprises a pushing member movable along a bench
  • said indexing means and said loading device include a pushing member actuator capable of moving said pushing member between a first position adjacent a loading position of said first carrousel and a second position adjacent a loading position of said second carrousel, whereby said pushing member is destined to load concrete blocks located on said bench in a drum indexed at said loading position of said first carrousel when said pushing member is moved from said second position towards said first position, and in a drum located at said loading position of said second carrousel when said pushing member is moved from said first position towards said second position.
  • said unloading means includes an inclined inner wall of said drums, with said drums rotating about a generally horizontal axis, said inner wall of each said drum defining a frustoconical shape having a diametrically larger mouth opening and a diametrically smaller end blocked by an end wall, each said drum thus being destined to bias concrete blocks being tumbled therein towards said mouth opening, said unloading means further comprising a retaining wall carried by said frame and closing said mouth openings of said drums, said retaining wall however comprising a loading opening allowing drums to be loaded therethrough according to said predetermined loading sequence and an unloading opening allowing drums to be unloaded therethrough according to said predetermined unloading sequence.
  • said first drum comprises a movable partition therein allowing said first drum to be divided into first and second drum portions for allowing a first and a second batch of concrete blocks to be tumbled separately respectively within said first and second portions of said first drum, said first drum comprising an inlet opening for allowing blocks to be fed into said first drum portion and an outlet opening for allowing blocks to be expelled out of said second drum portion.
  • the present invention also relates to a method for batch processing concrete blocks through a tumbling apparatus, said tumbling apparatus comprising a number of rotatable drums, said tumbling apparatus being located adjacent a loading device for loading concrete blocks in said rotatable drums, said method comprising the steps of: a) conveying concrete blocks to said loading device; b) adjusting the relative position of said drums and said loading device for loading concrete blocks in selected ones of said drums according to a predetermined loading sequence; c) loading said concrete blocks in selected ones of said drums according to said predetermined loading sequence, each drum being loaded with one batch of concrete blocks; d) revolving said drums to tumble, and thus resurface, the concrete blocks located therein, said tumbling apparatus having the capacity to tumble a number of batches of blocks simultaneously in separate drums; and e) unloading said drums according to a predetermined unloading sequence.
  • Figure 1 is a schematic top plan view of a concrete block resurfacing system according to the invention
  • Figure 2 is an enlarged side elevational view of the pallet unloading mechanism, the feed conveyor, and the loading device of the block resurfacing system of figure 1;
  • Figure 3 is an enlarged partial top plan view of the feed conveyor and the loading device
  • Figure 4 is an enlarged perspective view of the two tumbling apparatuses of the block resurfacing system of figure 1, with the front wall of one of the tumbling apparatuses being only partly shown and the front wall of the other tumbling apparatus being removed;
  • Figure 5 is an view similar to that of figure 4, but showing integrally the front wall of each tumbling apparatus
  • Figure 6 is a partial rear elevational view of one of the tumbling apparatuses of figure 4.
  • Figure 7 is a top plan view of the tumbling apparatuses of figure 5;
  • Figures 8 and 9 show enlarged partial rear and front perspective views respectively of the drum-provided carousel of the tumbling, apparatus of figure 5, illustrating the detail of two drums attached to the carousel;
  • Figures 10 and 11 are schematic partial views of an alternate embodiment of a concrete block resurfacing system according to the present invention, respectively showing atop plan view and an end elevation of the system.
  • Block resurfacing system 20 comprises a linear inlet conveyor 22 of known construction, e.g. of the type comprising a driven endless belt, conveyor 22 having an upstream end 22a and a downstream end 22b and defining an inlet conveyor axis 21.
  • Inlet conveyor 22 is destined to convey pallets of stacked concrete blocks towards its downstream end 22b, where a pallet unload mechanism 24 is stationed.
  • the downstream direction will refer to the direction indicated by arrows A in the figures.
  • the concrete blocks to be processed are stacked in a conventional manner on wooden pallets so as to form a parallelepiped-shaped stack of blocks (see for example figure 2).
  • This so-called palletized block stack comprises a plurality of superimposed layers of blocks.
  • Each layer has a uniform thickness, and therefore all blocks from a given layer have an identical thickness. This does not exclude the fact that the thickness of the blocks may vary from one layer to another.
  • each layer is composed of a number of elongated rows of blocks packed side by side. The orientation of the rows can vary on the pallet; for example, the rows of a first layer of a palletized block stack can be arranged lengthways on the pallet, while the rows of another layer of the same palletized block stack may be oriented widthways on the pallet.
  • pallet unload mechanism 24, located downstream of inlet conveyor 22, comprises an actuated elevating platform 25, which can move vertically upon activation of a lift mechanism 25a, between a lower limit position and an upper limit position (in figure 2, platform 25 is shown in its lower limit position). It is to be noted that the top operative surface area of elevating platform 25 is vast enough to accommodate a palletized block stack thereon comprising a number of blocks B. In one embodiment, platform 25 is substantially as wide as inlet conveyor 22.
  • Pallet unload mechanism 24 further comprises a framework 26, to which an overhead push-plate carriage 28 is rollably mounted by means of a conventional wheel- and-rail type linear slidable engagement for example.
  • An elbowed front push plate 30 is pivotally mounted at the front end of push-plate carriage 28, and an elbowed rear push- plate 32 is pivotally attached at the rear end of push-plate carriage 28.
  • Push-plates 30, 32 extend transversely across push-plate carriage 28, and have a length approximately equal to the width of elevating platform 25.
  • Push-plate actuators 31, 33 can be selectively activated to pivot push-plates 30, 32 between an upper retracted limit position and a lower operative limit position.
  • Carriage actuators can forcibly slide push-plate carriage 28 about its linearly slidable engagement to framework 26, between a first limit position shown in dotted lines in figure 2 and referred to with primed reference numerals where push-plate carriage 28 overhangs platform 25, and a second limit position shown in full lines in figure 2 and referred to with non-primed numerals where push-plate carriage 28 overhangs a turntable device 36.
  • Turntable device 36 can be driven by suitable drive means (not shown in the figures) connected to its downwardly-projecting central shaft 36a to pivot about a turntable pivot axis 38 relative to framework 26.
  • Turntable device 36 will be used to selectively rotate concrete blocks, pushed from a palletized block stack located on platform 25 onto turntable device 36 by rear push-plate 32, as described hereinafter.
  • the stack of blocks B fed to pallet unload mechanism 24 is composed of a number of layers each having a specific thickness, each layer being in turn composed of a number of rows of blocks B oriented in a specific direction and each having a specific width.
  • Such pallet configuration data is programmed into computer means (not shown) operating pallet unload mechanism 24 prior to loading a palletized block stack therein. Consequently, when a palletized block stack is fed to pallet unloading mechanism 24, the thickness of each of its layers, the width of each of its rows and their orientation, is known by the computer means, and this computer means can command the actuators driving elevating platform 25, turntable device 36, and push-plate carriage 28 according to this geometrical data.
  • a transverse conveyor 118 conveys the pallet in the downstream direction, for the eventual re-palletizing of the resurfaced blocs, as described hereinafter.
  • FIGS 2-3 further show that a feed conveyor 40 is provided downstream of turntable device 36; feed conveyor 40 can be of the driven endless belt type for example. Feed conveyor 40 can be selectively activated by suitable actuating means, and is destined to convey one or more rows of concrete blocks towards a loading device 42.
  • Loading device 42 comprises an elongated trough-like, V-shaped loading bench 44, formed of two sloped intersecting walls 44a and 44b forming a 90-degree angle for example.
  • Elongated loading bench 44 extends perpendicularly to inlet conveyor axis 21.
  • Loading device 42 further comprises a pushing member 46, which in turn comprises two parallel spaced-apart push plates 46a and 46b (as shown in figure 3), secured to a pushing member main body 46c.
  • Push plates 46a and 46b have a geometry complementary to that of V-shaped loading bench 44, and thus snugly yet slidably engage the trough formed by walls 44a and 44b of loading bench 44.
  • Pushing member body 46c is slidably mounted to a stationary straight track member 48 parallel to elongated loading bench 44, and attached to wall 44b (figure 2).
  • a linear actuator (not shown) is provided on loading device 42 to forcibly and linearly slide pushing member 46 about track member 48 between a first limit position in which pushing member 46 is located at one extremity of bench 44 and a second limit position in which pushing member 46 is located at the opposite extremity of bench 44.
  • pushing member 46 is illustrated in a position intermediate its first and second limit positions.
  • a pair of tumbling apparatuses 60, 60 are installed on both sides of loading device 48.
  • each tumbling apparatus 60 comprises a stationary frame 61, which in turn comprises a three-legged ground resting stand 64.
  • a horizontal shaft 65 extends between and is fixedly mounted to both legged stands 64, 64 of tumbling apparatuses 60, 60.
  • a gear 67 is integrally coupled to shaft 65 behind each tumbling apparatus 60 (one gear is concealed in figures 4 and 5), and is located adjacent its corresponding stand 64.
  • Gear 67 is operatively linked, through a endless drive chain (not shown), to a carousel actuator 69 (see figure 7).
  • Each tumbling apparatus 60 further comprises a carousel 62 a carousel hub 66 rotatably mounted to shaft 65.
  • carousel actuators 69 being activated, both carousels 62, 62 are rotated in unison about shaft 65 and about a horizontal carousel rotation axis 77.
  • Each carousel 62 comprises a rotatable frame in turn comprising a circular front rim 68, integrally connected to a rear polygonal rim 70 by transverse linking bars 72 which keep rims 68 and 70 parallel to and spaced-apart from each other.
  • Front rim 68 is composed of a number of coextensive arcuate elongated front rim segments 76, attached at both ends to the outer ends of front spokes 74 radiating from carousel hub 66.
  • a front reinforcing square central brace assembly 78 surrounding carousel hub 66 is fixedly attached to all spokes 74.
  • Rear polygonal rim 70 is composed of a number of straight elongated rear rim segments 80, attached at both ends to the outer ends of rear spokes 82 radiating away from carousel hub 66.
  • a rear reinforcing square brace assembly 84 surrounding carousel hub 66 is fixedly attached to all rear spokes 82.
  • a number of frustoconical hollow planetary drums 86 are each rotatably mounted to rear polygonal rim 70 and are for use in tumbling concrete blocks therein.
  • each planetary drum 86 is formed of a number of side-by-side, edgewisely linked flat sheet metal side plates 86a firmly attached to a circular sheet metal base 86b.
  • Side plates 86a are arranged such that drums 86 define a substantially frustoconical shape, and each drum 86 thus has an open diametrically broader end, and a diametrically smaller end closed by circular base 86b.
  • each drum 86 further comprises in the vicinity of its open end a hoop 86c encircling assembled plates 86a.
  • An axle 88 is fixedly attached to circular base 86b of each drum 86 and extends outwardly of drum 86.
  • Axle 88 is journalled to a bearing located on a corresponding rear rim segment 80 so as to be rotatable about a drum rotation axis 71.
  • drum rotation axes 71 of all drums 86 are parallel to each other and to carousel rotation axis 77, with axes 77, 71 being substantially horizontal.
  • Axle 88 extends through and backwardly beyond rim segment 80.
  • Each planetary drum 86 is arranged such that it is located between two consecutive front spokes 74 and a corresponding arcuate front rim segment 76 of carousel 62 where, as seen in the enlarged views of figures 8-9, rollers 75a, 75b, 75c rollably carried by the carousel frame rollingly engage hoop 86c to guide the rotary movement of each drum 86 about rotation axis 71, and to support the front end portion of each drum 86.
  • a drum wheel 90 in the form of a rubber tire for example, is coaxially coupled to axle 88 of each drum 86, and can integrally rotate therewith about drum rotation axis 71.
  • Each drum wheel 90 rollingly engages a drive ring 92, which is supported by carousel 62 through the instrumentality of a circular array of roller-provided ring support members 94 fixedly carried by rear brace assembly 84. Ring 92 can thus rotate independently from carousel 62.
  • Drive ring 92 comprises two integral portions: a tire track portion 92a and a sprocket portion 92b, tire track portion 92a being closer to carousel 62 than sprocket portion 92b.
  • Tire track portion 92a has a double peripheral flange as seen in figure 7, so as to form a peripheral track engaged by tires 90 of drums 86.
  • Tires 90 being made of rubber or of another high-friction material, the rotation of drive-ring 92 and thus of this tire track portion 92a leads to a corresponding rotation of tires 90, and thus of drums 86 about their respective drum rotation axes 71, independently of the rotation of the carousel rotatable frame per se.
  • Sprocket portion 92b is snugly engaged by a flexible endless drive belt 96.
  • Drive belt 96 is provided with teeth on its inner surface which engage the sprockets of sprocket ring portion 92b, so as to establish a non-slidable relationship therewith.
  • Drive belt 96 can be selectively actuated by a stationary belt actuator 98. Accordingly, upon activation of belt actuator 98, belt 96 and thus drive ring 92 will be actuated, so as to rotate all tires 90 and hence all planetary drums 86 about drum their corresponding rotation axes 71.
  • Frame 61 of each tumbling apparatus 60 is further provided with a stationary front wall 63, as seen in figures 4-5.
  • Front walls 63, 63 of both tumbling apparatuses are in facing register with each other, and each comprises a substantially rectangular loading opening 100 and a substantially half-circle-shaped unloading opening 102; it is understood that other shapes of openings 100 and 102 could be envisioned in alternate embodiments.
  • the front wall 63 of each tumbling apparatus extends in front of front rim 68 is located in close proximity to the open end of drums 86, yet spacedly therefrom. Indeed, a small gap is present between the outer rim of drums 86 and front wall 63 (e.g. half an inch), for allowing concrete dust produced during the tumbling process to be continuously expelled from drums 86, as described hereinafter.
  • At most one given drum 86 at a time registers with loading opening 100 when it is in a so-called drum-loading position, while another drum 86 located adjacent this given drum 86 registers simultaneously with unloading opening 102 when it is in a so- called drum-unloading position.
  • loading opening 100 registers with loading bench 44 of loading device 42, more specifically, the two lower edges of loading opening 100 register exactly with sloped walls 44a, 44b of loading bench 44.
  • unloading opening 102 it is located above an outlet conveyor 110 illustrated in figure 1. As shown in figure 1, there are two outlet conveyors 110, 110 each destined to be used with the adjacent one of tumbling apparatuses 60, 60.
  • Outlet conveyors 110, 110 are destined to convey resurfaced blocks coming out of tumbling apparatuses 60, 60 in a disarrayed fashion, towards block-aligning machines 112, 112 of known construction. Downstream of these block-aligning machines 112, 112, a block-sorting station 114 of known construction is installed, and downstream of this block-sorting station 114, a palletizing station 117 is installed to palletize the resurfaced blocks on pallets fed from pallet conveyor 120.
  • a palletized block stack is placed onto inlet conveyor 22 by a forklift vehicle for example.
  • This palletized block stack will travel onto conveyor 22 and reach pallet unload mechanism 24, where the block-loaded pallet will be transferred onto elevating platform 25.
  • the computer means command the latter to be raised so that only the first layer of blocks extends vertically beyond the level of turntable device 36.
  • push-plates 30, 31 are upwardly pivoted towards their retracted position, in order to avoid the blocks as push-plate carriage 28 is driven by the carriage actuators towards its first limit position where it overhangs elevating platform 25.
  • Push-plates 30, 31 are then downwardly pivoted towards their operative position.
  • the computer means thereafter commands push-plate carriage 28 to be linearly displaced towards its second limit position, where it overhangs turntable device 36, in order for rear push plate 32 to push an entire layer of blocks from the pallet onto turntable device 36.
  • turntable device 36 is commanded by the computer means to rotate about turntable rotation axis 38 to orient the rows in a parallel fashion relative to elongated loading bench 44.
  • the above-described pallet elevating and layer-pushing steps are then repeated, so as to push a second layer of blocks onto turntable device 36.
  • front push-plate 30 will push the previously unloaded first layer of blocks towards feed conveyor 40.
  • Feed conveyor 40 is intermittently activated to feed rows of blocks placed thereon one at a time to loading device 42.
  • the first row of blocks placed on feed conveyor 40 will travel towards loading device 42 until the blocks extend over the downstream edge of the feed conveyor 40, downwardly tilt under their own weight and fall into loading bench 44.
  • pushing member 46 which lies at this point in one of its limit positions, e.g. its first limit position, will be slidably driven towards its second limit position, push plate 46a thereby pushing this row of blocks towards the registering loading opening 100 of one of the tumbling apparatuses 60.
  • carousel 62 has been suitably rotated so as to index the open end of a drum 86 in facing register with loading opening 100. Therefore, as pushing member 46 is slidably driven towards its second limit position, a row of concrete blocks is loaded into one drum 86.
  • pushing member 46 will be forcibly moved back towards its first limit position, the other push-plate 46b thereby pushing the second row of blocks into a drum 86 indexed before loading opening 100 at the drum-loading position of the opposite tumbling apparatus 60.
  • each drum 86 of both tumbling apparatuses 100, 100 continuously rotated about its drum rotation axis 71 by drive ring 92.
  • the concrete blocks consequently impact each other as drums 86 are revolved, in order to resurface the blocks, and thus provide them with the desired antique appearance.
  • the blocks will be superficially damaged by being chipped, marked and worn.
  • Drums 86 being frustoconical and horizontally disposed, drum plates 86a are inclined frontwardly outwardly. Accordingly, as block-filled drums 86 revolve, all blocks will be gravity-biased towards the diametrically broader open end of drums 86, hence promoting block impact while they are tumbled.
  • drums 86 will allow for the concrete dust released from the collision between the concrete block to be biased towards the open end of drums 86, and thus be evacuated through the gap formed between the outer rim of drums 86 and the front wall 63 of tumbling apparatus 60.
  • a dust collector unit (not shown) can be coupled to tumbling apparatus 60 to collect the concrete dust flowing out of drums 86.
  • each drum 86 will eventually be indexed before unloading opening 102 and thus be positioned in the drum-unloading position, at which point the concrete blocks will be expelled out of each drum 86 through unloading opening 102 due to the inclination of the drum inner wall.
  • the frustoconical shape of horizontal drums 86 ensure that the blocks are continuously gravity-biased towards the open end of drums 86.
  • This frustoconical shape thereby forms an unloading means for the drums 86.
  • drum-unloading means could be envisioned, such as a pushing device located within each drum 86 and forcibly pushing the blocks out when drum 86 passes before the unloading opening 102 made in front wall 63.
  • carousel 62 is rotated in a direction which allows for a drum 86, right after it has been loaded with blocks, to be moved away from unloading opening 102 and thus away from the drum-unloading position. Consequently, the blocks can be tumbled in a drum 86 while carousel 62 achieves almost an entire revolution before they are unloaded therefrom, which provides enough tumbling time for the blocks to be resurfaced to obtain the desired antique appearance.
  • each block-loaded drum 86 will inevitably pass by the drum-unloading position, and thus be unloaded, before it reaches the drum-loading position again to be reloaded with another batch of blocks. Consequently, drums 86 are always empty before they are loaded with blocks.
  • the blocks land on outlet conveyor 110 and are carried towards block-aligning machine 112, where they will be aligned.
  • the blocks are then forwarded to block-sorting station 114 where blocks which have been excessively damaged during the tumbling process are discarded by human inspectors, and finally to a block palletizing station 117, where the blocks are piled up in stacks and arranged on wooden pallets fed by pallet conveyor 120.
  • Prior art tumbling apparatuses comprise a single drum of large diameter in which a high number of blocks were tumbled together. As this large drum is revolved, the tumbled blocks can be excessively damaged as they are impacted upon with greater energy.
  • the present invention provides a solution for tumbling a similarly high number of blocks simultaneously, while diminishing the occurrence of blocks that become damaged excessively during the tumbling process. Indeed, the tumbling being accomplished in a plurality of smaller distinct drums, the velocity the tumbled blocks can reach within the drum is limited, and the risk that blocks become unusable because they have been too forcefully impacted upon by other blocks is greatly diminished.
  • any other suitable drive means could be used instead of the drive ring
  • each drum could be driven by an independent actuator, or the drums could be driven by the same drive means which drives the carousels in a rotary motion with suitable coupling means.
  • the present invention also relates to a method for handling concrete blocks and for tumbling the concrete blocks in the above-described tumbling apparatus 60.
  • This method comprises the steps of: a) rotating carousel 62 in order to index drums 86 successively, one at a time, at their drum-loading position; b) loading concrete blocks in each drum 86 when it is indexed at its drum-loading position; c) revolving drums 86 to tumble, and thus resurface the concrete blocks located therein; d) rotating carousel 62 in order to index drums 86 successively at their drum-unloading position; and e) unloading blocks from each drum 86 when it is indexed at its drum-unloading position.
  • block resurfacing system 200 is partly shown in figures 10 and 11, wherein the following elements similar to those of the first embodiment 20 are used: an inlet conveyor 22, a pallet unload mechanism 24 including an overhead push plate carriage (not shown in figures 10-11), a turntable device 36 and a feed conveyor 40.
  • block resurfacing system 200 includes a tumbling apparatus 250 including a number of drums, for example four drums 252a, 252b, 252c, 252d, generally referred to as drums 252.
  • Drums 252 are rotatably mounted to a fixed, ground-resting frame (not shown in the schematic views of figures 10-11) so as to be rotatable about respective drum rotation axes.
  • Drums 252 are otherwise stationary, i.e. their axes remain immobile relative to their support frame.
  • Each drum 252, for example drum 252d, comprises a movable partition 253 at an intermediate portion thereof that divides drum 252d into first and second drum portions 254, 256.
  • Drum 252 also comprises an inlet opening 258 for allowing blocks to be fed into the first drum portion 254 and an outlet opening 260 for allowing blocks to be expelled out of the second drum portion 256.
  • a hopper 262 is fixedly attached to drum 252d at its inlet opening 258, and a drum conveyor 264, which may be for example a belt conveyor, extends between loading device 42 and hopper 262.
  • An outlet door 266 selectively closes outlet opening 260 and in an opened condition it provides access from second drum portion 256 to an outlet conveyor 210 that is shared by all drums 252.
  • Drums 252 are inclined towards outlet conveyor 210.
  • first loading device 42' including a bench, a reciprocating pushing member and an actuator similar to those of loading device 42 of the first embodiment, with the exception that the loading device bench of first loading device 42' is flat and coplanar with feed conveyor 40 instead of forming a trough.
  • the pushing member of this loading device 42' is correspondingly sized and configured to push rows of blocks to either side of loading device 42' along this flat bench. Loading device 42' is only shown in figure 10 since it is concealed in figure 11.
  • a second loading device 42" similar to first loading device 42' is further provided downstream of first loading device 42', with the second loading device 42" being only shown in figure 11 since it is removed in figure 10 to allow the underlying portion of outlet conveyor 210 to be illustrated.
  • First loading device 42' is aligned and used in cooperation with the first and second drums 252a, 252b, while second loading device 42" is aligned and used in cooperation with the third and fourth drums 252c, 252d.
  • a concrete block-loaded pallet is suitably conveyed to inlet conveyor 22, the latter forwarding the pallet to pallet unloading mechanism 24 from where layers of blocks will be dispatched onto feed conveyor 40, as described in the case of the first embodiment of the invention.
  • the blocks will be conveyed by feed conveyor 40 to a selected one of loading device 42' and loading device 42" - for example the rows of blocks may be fed by pairs, one row of block for each loading device 42', 42".
  • Loading device 42', 42" will then move their pushing member from their first to their second limit positions to move the blocks from their benches onto the drum conveyors 264 of a pair of corresponding drums, for example drums 252b, 252d.
  • Each drum conveyor 264 conveys blocks loaded thereon into its corresponding hopper 262 which will redirect the blocks through the drum inlet opening 258 and into the first drum portion 254.
  • Drums 252b, 252d continuously rotating, the blocks therein will be tumbled, and thus resurfaced, within first drum portions 254.
  • the movable partitions 253 of drums 252b, 252d will be opened, which will allow the blocks to be biased along the inclined drums 252b, 252d from the first drum portions 254 to the second drum portions 256.
  • the movable partitions 253 are then closed, to allow the first drum portions 254 to be fed with another batch of blocks from loading devices 42', 42" and feed conveyors 264. Meanwhile, the first batch of blocks continues to be tumbled, and consequently resurfaced, within the second drum portion 256. Consequently, two distinct batches of blocks may be tumbled simultaneously although separately within each drum 252.
  • the outlet doors 266 of drums 252b, 252d are opened, and the first batches of blocks corresponding to the two first rows of blocks that were loaded in drums 252b, 252d are expelled out of the second drum portions 256 onto outlet conveyor 210, on which they are conveyed towards a palletizing station (not shown).
  • loading devices 42', 42" will feed rows of blocks to drums 252a, 252c that will operate in a similar manner than that described hereinabove for drums 252b, 252d, although the batches of blocks will be resurfaced within drums 252a, 252c in an offset timing relative to those in drums 252b, 252d due to the alternate loading sequences of loading devices 42', 42" that alternately load drums 252b, 252d and drums 252a, 252c.
  • An alternate loading device could also be provided in block resurfacing system 200, including a single bench, pushing member and actuator assembly longitudinally movable along feed conveyor 40 to alternately load all drums 252a, 252b, 252c, 252d.
  • the present invention thus also relates to a block resurfacing system for resurfacing concrete blocks that comprises: a feed conveyor defining a downstream end towards which the blocks are destined to be conveyed.
  • This feed conveyor has been shown as a belt conveyor in the drawings, although it is understood that any suitable type of conveying apparatus would be acceptable. It is understood that the feed conveyor may also extend downstream of the loading device, whereby this conveyor would also act as an outlet conveyor. In such a case, the feed conveyor downstream end is considered to be the portion of the conveyor at which the blocks are fed to the tumbling apparatus; a frame.
  • This frame may be unitary or separated into different frame portions; a tumbling apparatus comprising a number of rotatable drums mounted to the frame and destined to tumble concrete blocks for resurfacing the concrete blocks.
  • This tumbling apparatus will include at least two drums that allow distinct batches of blocks to be separately although simultaneously tumbled.
  • the rotatable drums may be movable, for example if they are installed on a carrousel, or fixed, for example if they are aligned along the feed conveyor; - a loading device adjacent the feed conveyor downstream end, for loading concrete blocks in the drums.
  • any alternate suitable device capable of loading blocks into the drums is acceptable; indexing means capable of selectively adjusting the relative position of the loading device and the drums for loading concrete blocks in selected ones of the drums according to a predetermined loading sequence.
  • the indexing means could include a simple programmed timing of the pushing member of the loading device, whereby two drums located on either side of the pushing member would be alternately loaded with blocks.
  • the blocks would be tumbled within the rotatable drums that would remain otherwise stationary, and expelled before a new batch of blocks is loaded within each of the two drums; and unloading means cooperating with the drums for unloading the drums according to a predetermined unloading sequence.
  • Any suitable type of automatic or controlled unloading device may serve as an unloading means.
  • the invention also relates to a method for batch processing concrete blocks through a tumbling apparatus, the tumbling apparatus comprising a number of rotatable drums, the tumbling apparatus being located adjacent a loading device for loading concrete blocks in the rotatable drums, the method comprising the steps of: a) adjusting the relative position of the drums and the loading device for loading concrete blocks in selected ones of the drums according to a predetermined loading sequence.
  • the loading device may be movable, the drums may be movable, or the loading device and the drums may be movable; b) loading the concrete blocks in selected ones of the drums according to the predetermined loading sequence, each drum being loaded with one batch of concrete blocks.
  • Each batch of concrete blocks may comprise any pre-determined number of blocks; c) revolving the drums to tumble, and thus resurface, the concrete blocks located therein, the tumbling apparatus having the capacity to tumble a number of batches of blocks simultaneously in separate drums; and d) unloading the drums according to a predetermined unloading sequence.
  • one particular advantage brought about by the automated concrete block resurfacing system of the present invention is that it allows batches of blocks to be resurfaced separately, although simultaneously.
  • the blocks may be expelled from the tumbling apparatus in the order in which they were inserted therein, thus allowing the blocks to be easily sorted after they were tumbled, which may allow the blocks to be re-palletized without requiring any human intervention.

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Abstract

The block resurfacing system (20) comprises a feed conveyor defining a downstream end towards which the blocks are destined to be conveyed, a frame (6), a tumbling apparatus (60) comprising a number of rotatable drums (86) mounted to the frame (6) and destined to tumble concrete blocks for resurfacing the concrete blocks, a loading device (42) adjacent the feed conveyor (40) downstream end, for loading concrete blocks from the feed conveyor (40) into the drums (86), an indexing device (62) capable of selectively adjusting the relative position of the loading device (42) and the drums (86) for loading concrete blocks in selected ones of the drums (86) according to a predetermined loading sequence, and an unloading device (63, 102) cooperating with the drums (86) for unloading the drums (86) according to a predetermined unloading sequence.

Description

TITLE OF THE INVENTION: METHOD AND APPARATUS FOR RESURFACING CONCRETE BLOCKS
CROSS-REFERENCE DATA
The present patent application claims the priority under the Paris Convention of co-pending American provisional patent application No. 60/442,807 filed on January 28, 2003.
FIELD OF THE INVENTION
The present invention relates to methods and systems for resurfacing concrete blocks, and more particularly to a method and system for handling and tumbling concrete blocks so as to provide them with an antique appearance.
BACKGROUND OF THE INVENTION
Concrete blocks resurfacing machines are used to provide a so-called antique look to concrete blocks, by artificially wearing and chipping the visible outer surfaces of the concrete blocks so as to provide them with a similar rough appearance than that of wild, naturally developed stone blocks.
Amongst other methods, the artificial wearing of concrete blocks can be done by tumbling the blocks in a large hollow rotating drum wherein a number of blocks are inserted. As the drum rotates, the blocks will collide within the drum, thus damaging one another and wearing their outer surfaces to provide the desired antique appearance. A problem with these rudimentary tumbling apparatuses is that the concrete blocks are often damaged to an extent that they cannot be used for their intended structural purpose anymore. Moreover, these tumbling apparatuses lack automation as they cannot be used in cooperation with block handling equipment. Indeed, after having been processed in the tumbling apparatus, the blocks come out of the apparatus in a disorderly fashion, and workmen have to manually pick up the usable blocks and arrange them in the proper order for the blocks to be palletized, while discarding the blocks which have been exceedingly damaged during the tumbling process. A need exists for a new and improved tumbling apparatus which can be used in cooperation with block handling equipment, in order to increase the degree of automation of the artificial block-wearing process and thus diminish the amount of manual labour required to achieve it.
SUMMARY OF THE INVENTION
The present invention relates to a block resurfacing system comprising a tumbling apparatus and a loading device, said tumbling apparatus comprising:
- a frame;
- a carousel rotatably mounted to said frame so as to be rotatable about a carousel rotation axis;
- a number of hollow planetary drums each rotatably mounted to said carousel so as to be rotatable about a corresponding drum rotation axis, and destined to be loaded with concrete blocks by said loading device;
- first drive means capable of selectively rotating said carousel about said carousel rotation axis in order to selectively move each said planetary drum between a drum- loading position and a drum-unloading position; and
- second drive means capable of selectively rotating each said planetary drum about said corresponding drum rotation axis; wherein said loading device can be selectively activated for loading concrete blocks in each said drum positioned in said drum-loading position, wherein each said drum can be unloaded when it is positioned in said drum-unloading position, and wherein said second drive means can be activated for tumbling and consequently resurfacing concrete blocks located in said drums.
In one embodiment, said block resurfacing system further comprises drum- unloading means for unloading concrete blocks from each said drum positioned in said drum-unloading position.
In one embodiment, said frame comprises an upright stationary front wall installed adjacent said carousel, each said drum positioned in said drum-loading position registers with a loading opening made in said front wall, and each said drum positioned in said drum-unloading position registers with a drum-unloading opening made in said front wall. In one embodiment, all of said drum rotation axes and said carousel rotation axis are mutually parallel and substantially horizontal.
In one embodiment, said unloading means comprises a frustoconical shape of each said drum, each said drum thus defining a diametrically smaller end and a diametrically broader end, and said frustoconical shape of each said drum is destined to allow concrete blocks located in each said drum to be continuously gravity-biased towards said diametrically broader end of each said drum.
In one embodiment, said diametrically broader end of each said drum is open, and said diametrically broader end of each said drum positioned in said drum- unloading position is juxtaposed to said housing unloading opening, for allowing concrete blocks to be unloaded from each said drum positioned in said drum-unloading position by passing through said diametrically broader open end of said drum, through said housing unloading opening and thus out of said tumbling apparatus.
In one embodiment, said loading device is a block-pushing mechanism. The present invention also relates to a block resurfacing system comprising a feed conveyor for conveying concrete blocks towards a first tumbling apparatus and an outlet conveyor for conveying concrete blocks away from said first tumbling apparatus, and further comprising a loading device, said first tumbling apparatus comprising:
- a frame; - a carousel rotatably mounted to said frame so as to be rotatable about a carousel rotation axis;
- a set of hollow planetary drums each rotatably mounted to said carousel so as to be rotatable about a corresponding drum rotation axis, and destined to be loaded with concrete blocks by said loading device; - first drive means capable of selectively rotating said carousel about said carousel rotation axis in order to selectively move each said planetary drum between a drum- loading position and a drum-unloading position; and
- second drive means capable of selectively rotating each said planetary drum about said corresponding drum rotation axis; wherein said feed conveyor can be activated for conveying concrete blocks to said first tumbling apparatus and for engaging them in said loading device, wherein said loading device can be selectively activated for loading concrete blocks in each said drum positioned in said drum-loading position, wherein each said drum can be unloaded when it is positioned in said drum-unloading position, wherein said second drive means can be activated for tumbling concrete blocks located in each said drum, and wherein said outlet conveyor can be activated for conveying concrete blocks away from said first tumbling apparatus after having been unloaded from said set of planetary drums.
In one embodiment, said block resurfacing system further comprises a second tumbling apparatus comprising:
- a second frame; - a second carousel rotatably mounted to said second frame so as to be rotatable about a second carousel rotation axis;
- a second set of hollow planetary drums each rotatably mounted to said second carousel so as to be rotatable about a corresponding drum rotation axis, and destined to be loaded with concrete blocks; - third drive means capable of selectively rotating said second carousel about said second carousel rotation axis in order to selectively move each said drum of said second set of planetary drums between a second drum-loading position and a second drum-unloading position; and
- fourth drive means capable of selectively rotating each said planetary drum of said second set of planetary drums about said corresponding drum rotation axis. wherein each said drum of said second set of planetary drums can be loaded when it is in said second drum-loading position, wherein each said drum of said second set of planetary drums can be unloaded when it is positioned in said second drum-unloading position, and wherein said fourth drive means can be activated for tumbling and consequently resurfacing concrete blocks located in said drums of said second set of planetary drums.
In one embodiment, said feed conveyor is common to both said first and said second tumbling apparatuses.
In one embodiment, said loading device is common to both said first and said second tumbling apparatuses. The present invention also relates to a method for handling concrete blocks and for tumbling the concrete blocks in a tumbling apparatus, said tumbling apparatus comprising a carousel rotatably mounted to a frame, a number of planetary drums each rotatably mounted to said carousel, said tumbling apparatus being located adjacent a loading device for loading concrete blocks in said planetary drums, said method comprising the steps of: rotating said carousel in order to successively index said drums at a drum-loading position; loading concrete blocks in each said drum when it is indexed at said drum-loading position; revolving said drums to tumble, and thus resurface the concrete blocks located therein; - rotating said carousel in order to index said drums successively at a drum-unloading position; and unloading blocks from each said drum when it is indexed at said drum-unloading position.
In one embodiment, said drums revolve continuously. In another embodiment, in step e), said blocks are unloaded from said drums by being expelled therefrom due to the drums being frustoconical in shape, horizontally disposed and rotated about a horizontal axis, the drums having a larger front mouth opening for loading and unloading purposes.
The present invention more generally relates to a block resurfacing system for resurfacing concrete blocks, comprising: a feed conveyor defining a downstream end towards which the blocks are destined to be conveyed; a frame; a tumbling apparatus comprising a number of rotatable drums mounted to said frame and destined to tumble concrete blocks for resurfacing the concrete blocks; a loading device adjacent said feed conveyor downstream end, for loading concrete blocks from said feed conveyor into said drums; indexing means capable of selectively adjusting the relative position of said loading device and said drums for loading concrete blocks in selected ones of said drums according to a predetermined loading sequence; and unloading means cooperating with said drums for unloading said drums according to a predetermined unloading sequence. In one embodiment, said loading device comprises a pushing member movable along a bench, and said indexing means and said loading device include a pushing member actuator capable of moving said pushing member between a first position adjacent a first drum and a second position adjacent a second drum, whereby said pushing member is destined to load concrete blocks located on said bench in said first drum when said pushing member is moved from said second position towards said first position, and in said second drum when said pushing member is moved from said first position towards said second position.
In one embodiment, said indexing means comprises a first carousel rotatably mounted to said frame and rotatably carrying a number of said drums, said first carrousel being discretely rotated to allow said drums to be loaded by said loading device according ι to said predetermined loading sequence, and said first carrousel further being discretely rotated to allow said drums to be unloaded by said unloading means according to said predetermined unloading sequence. In one embodiment, said indexing means further comprises a' second carousel rotatably mounted to said frame and rotatably carrying a number of additional said drums, said second carrousel being discretely rotated to allow said additional drums to be loaded by said loading device according to said predetermined loading sequence, and said second carrousel further being discretely rotated to allow said additional drums to be unloaded by said unloading means according to said predetermined unloading sequence.
In one embodiment, said loading device comprises a pushing member movable along a bench, and said indexing means and said loading device include a pushing member actuator capable of moving said pushing member between a first position adjacent a loading position of said first carrousel and a second position adjacent a loading position of said second carrousel, whereby said pushing member is destined to load concrete blocks located on said bench in a drum indexed at said loading position of said first carrousel when said pushing member is moved from said second position towards said first position, and in a drum located at said loading position of said second carrousel when said pushing member is moved from said first position towards said second position. In one embodiment, said unloading means includes an inclined inner wall of said drums, with said drums rotating about a generally horizontal axis, said inner wall of each said drum defining a frustoconical shape having a diametrically larger mouth opening and a diametrically smaller end blocked by an end wall, each said drum thus being destined to bias concrete blocks being tumbled therein towards said mouth opening, said unloading means further comprising a retaining wall carried by said frame and closing said mouth openings of said drums, said retaining wall however comprising a loading opening allowing drums to be loaded therethrough according to said predetermined loading sequence and an unloading opening allowing drums to be unloaded therethrough according to said predetermined unloading sequence.
In one embodiment, said first drum comprises a movable partition therein allowing said first drum to be divided into first and second drum portions for allowing a first and a second batch of concrete blocks to be tumbled separately respectively within said first and second portions of said first drum, said first drum comprising an inlet opening for allowing blocks to be fed into said first drum portion and an outlet opening for allowing blocks to be expelled out of said second drum portion.
The present invention also relates to a method for batch processing concrete blocks through a tumbling apparatus, said tumbling apparatus comprising a number of rotatable drums, said tumbling apparatus being located adjacent a loading device for loading concrete blocks in said rotatable drums, said method comprising the steps of: a) conveying concrete blocks to said loading device; b) adjusting the relative position of said drums and said loading device for loading concrete blocks in selected ones of said drums according to a predetermined loading sequence; c) loading said concrete blocks in selected ones of said drums according to said predetermined loading sequence, each drum being loaded with one batch of concrete blocks; d) revolving said drums to tumble, and thus resurface, the concrete blocks located therein, said tumbling apparatus having the capacity to tumble a number of batches of blocks simultaneously in separate drums; and e) unloading said drums according to a predetermined unloading sequence.
DESCRIPTION OF THE DRAWINGS
In the annexed drawings : Figure 1 is a schematic top plan view of a concrete block resurfacing system according to the invention;
Figure 2 is an enlarged side elevational view of the pallet unloading mechanism, the feed conveyor, and the loading device of the block resurfacing system of figure 1;
Figure 3 is an enlarged partial top plan view of the feed conveyor and the loading device;
Figure 4 is an enlarged perspective view of the two tumbling apparatuses of the block resurfacing system of figure 1, with the front wall of one of the tumbling apparatuses being only partly shown and the front wall of the other tumbling apparatus being removed;
Figure 5 is an view similar to that of figure 4, but showing integrally the front wall of each tumbling apparatus;
Figure 6 is a partial rear elevational view of one of the tumbling apparatuses of figure 4;
Figure 7 is a top plan view of the tumbling apparatuses of figure 5;
Figures 8 and 9 show enlarged partial rear and front perspective views respectively of the drum-provided carousel of the tumbling, apparatus of figure 5, illustrating the detail of two drums attached to the carousel; Figures 10 and 11 are schematic partial views of an alternate embodiment of a concrete block resurfacing system according to the present invention, respectively showing atop plan view and an end elevation of the system.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Figure 1 shows a concrete block resurfacing system 20. Block resurfacing system 20 comprises a linear inlet conveyor 22 of known construction, e.g. of the type comprising a driven endless belt, conveyor 22 having an upstream end 22a and a downstream end 22b and defining an inlet conveyor axis 21. Inlet conveyor 22 is destined to convey pallets of stacked concrete blocks towards its downstream end 22b, where a pallet unload mechanism 24 is stationed. Throughout the present text, the downstream direction will refer to the direction indicated by arrows A in the figures. The concrete blocks to be processed are stacked in a conventional manner on wooden pallets so as to form a parallelepiped-shaped stack of blocks (see for example figure 2). This so-called palletized block stack comprises a plurality of superimposed layers of blocks. Each layer has a uniform thickness, and therefore all blocks from a given layer have an identical thickness. This does not exclude the fact that the thickness of the blocks may vary from one layer to another. Also, each layer is composed of a number of elongated rows of blocks packed side by side. The orientation of the rows can vary on the pallet; for example, the rows of a first layer of a palletized block stack can be arranged lengthways on the pallet, while the rows of another layer of the same palletized block stack may be oriented widthways on the pallet.
As shown in figure 2, pallet unload mechanism 24, located downstream of inlet conveyor 22, comprises an actuated elevating platform 25, which can move vertically upon activation of a lift mechanism 25a, between a lower limit position and an upper limit position (in figure 2, platform 25 is shown in its lower limit position). It is to be noted that the top operative surface area of elevating platform 25 is vast enough to accommodate a palletized block stack thereon comprising a number of blocks B. In one embodiment, platform 25 is substantially as wide as inlet conveyor 22.
Pallet unload mechanism 24 further comprises a framework 26, to which an overhead push-plate carriage 28 is rollably mounted by means of a conventional wheel- and-rail type linear slidable engagement for example. An elbowed front push plate 30 is pivotally mounted at the front end of push-plate carriage 28, and an elbowed rear push- plate 32 is pivotally attached at the rear end of push-plate carriage 28. Push-plates 30, 32 extend transversely across push-plate carriage 28, and have a length approximately equal to the width of elevating platform 25. Push-plate actuators 31, 33 can be selectively activated to pivot push-plates 30, 32 between an upper retracted limit position and a lower operative limit position.
Carriage actuators (not shown) can forcibly slide push-plate carriage 28 about its linearly slidable engagement to framework 26, between a first limit position shown in dotted lines in figure 2 and referred to with primed reference numerals where push-plate carriage 28 overhangs platform 25, and a second limit position shown in full lines in figure 2 and referred to with non-primed numerals where push-plate carriage 28 overhangs a turntable device 36. Turntable device 36 can be driven by suitable drive means (not shown in the figures) connected to its downwardly-projecting central shaft 36a to pivot about a turntable pivot axis 38 relative to framework 26. Turntable device 36 will be used to selectively rotate concrete blocks, pushed from a palletized block stack located on platform 25 onto turntable device 36 by rear push-plate 32, as described hereinafter.
As described hereinabove, the stack of blocks B fed to pallet unload mechanism 24 is composed of a number of layers each having a specific thickness, each layer being in turn composed of a number of rows of blocks B oriented in a specific direction and each having a specific width. Such pallet configuration data is programmed into computer means (not shown) operating pallet unload mechanism 24 prior to loading a palletized block stack therein. Consequently, when a palletized block stack is fed to pallet unloading mechanism 24, the thickness of each of its layers, the width of each of its rows and their orientation, is known by the computer means, and this computer means can command the actuators driving elevating platform 25, turntable device 36, and push-plate carriage 28 according to this geometrical data.
As shown in figure 1, after a block-loaded pallet is fed to pallet unload mechanism 24 and fully unloaded as described hereinafter, the pallet is conveyed by a transverse conveyor 118 to a pallet conveyor 120. The latter then conveys the pallet in the downstream direction, for the eventual re-palletizing of the resurfaced blocs, as described hereinafter.
Figures 2-3 further show that a feed conveyor 40 is provided downstream of turntable device 36; feed conveyor 40 can be of the driven endless belt type for example. Feed conveyor 40 can be selectively activated by suitable actuating means, and is destined to convey one or more rows of concrete blocks towards a loading device 42.
Loading device 42 comprises an elongated trough-like, V-shaped loading bench 44, formed of two sloped intersecting walls 44a and 44b forming a 90-degree angle for example. Elongated loading bench 44 extends perpendicularly to inlet conveyor axis 21. Loading device 42 further comprises a pushing member 46, which in turn comprises two parallel spaced-apart push plates 46a and 46b (as shown in figure 3), secured to a pushing member main body 46c. Push plates 46a and 46b have a geometry complementary to that of V-shaped loading bench 44, and thus snugly yet slidably engage the trough formed by walls 44a and 44b of loading bench 44. Pushing member body 46c is slidably mounted to a stationary straight track member 48 parallel to elongated loading bench 44, and attached to wall 44b (figure 2). A linear actuator (not shown) is provided on loading device 42 to forcibly and linearly slide pushing member 46 about track member 48 between a first limit position in which pushing member 46 is located at one extremity of bench 44 and a second limit position in which pushing member 46 is located at the opposite extremity of bench 44. In figure 3, pushing member 46 is illustrated in a position intermediate its first and second limit positions. As illustrated in figure 1, a pair of tumbling apparatuses 60, 60 are installed on both sides of loading device 48. With further reference to figures 4-9, each tumbling apparatus 60 comprises a stationary frame 61, which in turn comprises a three-legged ground resting stand 64. A horizontal shaft 65 extends between and is fixedly mounted to both legged stands 64, 64 of tumbling apparatuses 60, 60. A gear 67 is integrally coupled to shaft 65 behind each tumbling apparatus 60 (one gear is concealed in figures 4 and 5), and is located adjacent its corresponding stand 64. Gear 67 is operatively linked, through a endless drive chain (not shown), to a carousel actuator 69 (see figure 7).
Each tumbling apparatus 60 further comprises a carousel 62 a carousel hub 66 rotatably mounted to shaft 65. Upon the carousel actuators 69 being activated, both carousels 62, 62 are rotated in unison about shaft 65 and about a horizontal carousel rotation axis 77.
Each carousel 62 comprises a rotatable frame in turn comprising a circular front rim 68, integrally connected to a rear polygonal rim 70 by transverse linking bars 72 which keep rims 68 and 70 parallel to and spaced-apart from each other. Front rim 68 is composed of a number of coextensive arcuate elongated front rim segments 76, attached at both ends to the outer ends of front spokes 74 radiating from carousel hub 66. Furthermore, a front reinforcing square central brace assembly 78 surrounding carousel hub 66 is fixedly attached to all spokes 74. Rear polygonal rim 70 is composed of a number of straight elongated rear rim segments 80, attached at both ends to the outer ends of rear spokes 82 radiating away from carousel hub 66. A rear reinforcing square brace assembly 84 surrounding carousel hub 66 is fixedly attached to all rear spokes 82.
A number of frustoconical hollow planetary drums 86 are each rotatably mounted to rear polygonal rim 70 and are for use in tumbling concrete blocks therein. As illustrated in figures 8-9, each planetary drum 86 is formed of a number of side-by-side, edgewisely linked flat sheet metal side plates 86a firmly attached to a circular sheet metal base 86b. Side plates 86a are arranged such that drums 86 define a substantially frustoconical shape, and each drum 86 thus has an open diametrically broader end, and a diametrically smaller end closed by circular base 86b. Moreover, each drum 86 further comprises in the vicinity of its open end a hoop 86c encircling assembled plates 86a.
An axle 88 is fixedly attached to circular base 86b of each drum 86 and extends outwardly of drum 86. Axle 88 is journalled to a bearing located on a corresponding rear rim segment 80 so as to be rotatable about a drum rotation axis 71. In the embodiment shown in the figures, drum rotation axes 71 of all drums 86 are parallel to each other and to carousel rotation axis 77, with axes 77, 71 being substantially horizontal. Axle 88 extends through and backwardly beyond rim segment 80. Each planetary drum 86 is arranged such that it is located between two consecutive front spokes 74 and a corresponding arcuate front rim segment 76 of carousel 62 where, as seen in the enlarged views of figures 8-9, rollers 75a, 75b, 75c rollably carried by the carousel frame rollingly engage hoop 86c to guide the rotary movement of each drum 86 about rotation axis 71, and to support the front end portion of each drum 86.
As shown in figures 6-7, a drum wheel 90, in the form of a rubber tire for example, is coaxially coupled to axle 88 of each drum 86, and can integrally rotate therewith about drum rotation axis 71. Each drum wheel 90 rollingly engages a drive ring 92, which is supported by carousel 62 through the instrumentality of a circular array of roller-provided ring support members 94 fixedly carried by rear brace assembly 84. Ring 92 can thus rotate independently from carousel 62. Drive ring 92 comprises two integral portions: a tire track portion 92a and a sprocket portion 92b, tire track portion 92a being closer to carousel 62 than sprocket portion 92b. Tire track portion 92a has a double peripheral flange as seen in figure 7, so as to form a peripheral track engaged by tires 90 of drums 86. Tires 90 being made of rubber or of another high-friction material, the rotation of drive-ring 92 and thus of this tire track portion 92a leads to a corresponding rotation of tires 90, and thus of drums 86 about their respective drum rotation axes 71, independently of the rotation of the carousel rotatable frame per se.
Sprocket portion 92b is snugly engaged by a flexible endless drive belt 96. Drive belt 96 is provided with teeth on its inner surface which engage the sprockets of sprocket ring portion 92b, so as to establish a non-slidable relationship therewith. Drive belt 96 can be selectively actuated by a stationary belt actuator 98. Accordingly, upon activation of belt actuator 98, belt 96 and thus drive ring 92 will be actuated, so as to rotate all tires 90 and hence all planetary drums 86 about drum their corresponding rotation axes 71.
Frame 61 of each tumbling apparatus 60 is further provided with a stationary front wall 63, as seen in figures 4-5. Front walls 63, 63 of both tumbling apparatuses are in facing register with each other, and each comprises a substantially rectangular loading opening 100 and a substantially half-circle-shaped unloading opening 102; it is understood that other shapes of openings 100 and 102 could be envisioned in alternate embodiments. The front wall 63 of each tumbling apparatus extends in front of front rim 68 is located in close proximity to the open end of drums 86, yet spacedly therefrom. Indeed, a small gap is present between the outer rim of drums 86 and front wall 63 (e.g. half an inch), for allowing concrete dust produced during the tumbling process to be continuously expelled from drums 86, as described hereinafter.
At most one given drum 86 at a time registers with loading opening 100 when it is in a so-called drum-loading position, while another drum 86 located adjacent this given drum 86 registers simultaneously with unloading opening 102 when it is in a so- called drum-unloading position. Moreover, loading opening 100 registers with loading bench 44 of loading device 42, more specifically, the two lower edges of loading opening 100 register exactly with sloped walls 44a, 44b of loading bench 44. As for unloading opening 102, it is located above an outlet conveyor 110 illustrated in figure 1. As shown in figure 1, there are two outlet conveyors 110, 110 each destined to be used with the adjacent one of tumbling apparatuses 60, 60. Outlet conveyors 110, 110 are destined to convey resurfaced blocks coming out of tumbling apparatuses 60, 60 in a disarrayed fashion, towards block-aligning machines 112, 112 of known construction. Downstream of these block-aligning machines 112, 112, a block-sorting station 114 of known construction is installed, and downstream of this block-sorting station 114, a palletizing station 117 is installed to palletize the resurfaced blocks on pallets fed from pallet conveyor 120.
In use, to resurface concrete blocks using concrete block resurfacing system 20, a palletized block stack is placed onto inlet conveyor 22 by a forklift vehicle for example. This palletized block stack will travel onto conveyor 22 and reach pallet unload mechanism 24, where the block-loaded pallet will be transferred onto elevating platform 25. When a palletized block stack is loaded onto platform 25, the computer means command the latter to be raised so that only the first layer of blocks extends vertically beyond the level of turntable device 36. Then, push-plates 30, 31 are upwardly pivoted towards their retracted position, in order to avoid the blocks as push-plate carriage 28 is driven by the carriage actuators towards its first limit position where it overhangs elevating platform 25. Push-plates 30, 31 are then downwardly pivoted towards their operative position. The computer means thereafter commands push-plate carriage 28 to be linearly displaced towards its second limit position, where it overhangs turntable device 36, in order for rear push plate 32 to push an entire layer of blocks from the pallet onto turntable device 36.
If necessary, according to the orientation of the rows forming this first layer of blocks, turntable device 36 is commanded by the computer means to rotate about turntable rotation axis 38 to orient the rows in a parallel fashion relative to elongated loading bench 44. The above-described pallet elevating and layer-pushing steps are then repeated, so as to push a second layer of blocks onto turntable device 36. However, since the first layer of blocks has previously been placed on turntable device 36, as push-plate carriage 28 is driven towards its second limit position, front push-plate 30 will push the previously unloaded first layer of blocks towards feed conveyor 40. Feed conveyor 40 is intermittently activated to feed rows of blocks placed thereon one at a time to loading device 42. The first row of blocks placed on feed conveyor 40 will travel towards loading device 42 until the blocks extend over the downstream edge of the feed conveyor 40, downwardly tilt under their own weight and fall into loading bench 44. Once the row of blocks thus becomes seated in the trough formed by loading bench 44, pushing member 46, which lies at this point in one of its limit positions, e.g. its first limit position, will be slidably driven towards its second limit position, push plate 46a thereby pushing this row of blocks towards the registering loading opening 100 of one of the tumbling apparatuses 60. Of course, before this is done, carousel 62 has been suitably rotated so as to index the open end of a drum 86 in facing register with loading opening 100. Therefore, as pushing member 46 is slidably driven towards its second limit position, a row of concrete blocks is loaded into one drum 86.
Subsequently, as a second row of blocks is pushed on feed conveyor 40 and falls into loading bench 44, pushing member 46 will be forcibly moved back towards its first limit position, the other push-plate 46b thereby pushing the second row of blocks into a drum 86 indexed before loading opening 100 at the drum-loading position of the opposite tumbling apparatus 60.
As this process is accomplished, each drum 86 of both tumbling apparatuses 100, 100 continuously rotated about its drum rotation axis 71 by drive ring 92. The concrete blocks consequently impact each other as drums 86 are revolved, in order to resurface the blocks, and thus provide them with the desired antique appearance. Indeed, as drums 86 rotate and the blocks therein impact each other, the blocks will be superficially damaged by being chipped, marked and worn. Drums 86 being frustoconical and horizontally disposed, drum plates 86a are inclined frontwardly outwardly. Accordingly, as block-filled drums 86 revolve, all blocks will be gravity-biased towards the diametrically broader open end of drums 86, hence promoting block impact while they are tumbled. Moreover, such a frustoconical shape of the drums will allow for the concrete dust released from the collision between the concrete block to be biased towards the open end of drums 86, and thus be evacuated through the gap formed between the outer rim of drums 86 and the front wall 63 of tumbling apparatus 60. A dust collector unit (not shown) can be coupled to tumbling apparatus 60 to collect the concrete dust flowing out of drums 86.
As the blocks are tumbled within each drum 86, carousel 62 is meanwhile being pivoted about carousel rotation axis 77 in order to index successively each drums 86, one at a time, before loading opening 100. Also, as carousel 62 is pivoted about rotation axis 77, each drum 86 will eventually be indexed before unloading opening 102 and thus be positioned in the drum-unloading position, at which point the concrete blocks will be expelled out of each drum 86 through unloading opening 102 due to the inclination of the drum inner wall. Indeed, the frustoconical shape of horizontal drums 86 ensure that the blocks are continuously gravity-biased towards the open end of drums 86.
This frustoconical shape thereby forms an unloading means for the drums 86. In alternate embodiments, other drum-unloading means could be envisioned, such as a pushing device located within each drum 86 and forcibly pushing the blocks out when drum 86 passes before the unloading opening 102 made in front wall 63.
Of course, while indexing each drum successively at the drum-loading position, carousel 62 is rotated in a direction which allows for a drum 86, right after it has been loaded with blocks, to be moved away from unloading opening 102 and thus away from the drum-unloading position. Consequently, the blocks can be tumbled in a drum 86 while carousel 62 achieves almost an entire revolution before they are unloaded therefrom, which provides enough tumbling time for the blocks to be resurfaced to obtain the desired antique appearance. Also, with reference to this direction of rotation of the carousels 62, each block-loaded drum 86 will inevitably pass by the drum-unloading position, and thus be unloaded, before it reaches the drum-loading position again to be reloaded with another batch of blocks. Consequently, drums 86 are always empty before they are loaded with blocks.
Once a batch of blocks has fallen out of a given drum 86, the blocks land on outlet conveyor 110 and are carried towards block-aligning machine 112, where they will be aligned. The blocks are then forwarded to block-sorting station 114 where blocks which have been excessively damaged during the tumbling process are discarded by human inspectors, and finally to a block palletizing station 117, where the blocks are piled up in stacks and arranged on wooden pallets fed by pallet conveyor 120. Once all the layers of a block-loaded pallet has been unloaded, the empty pallet is taken away by transverse conveyor 118, platform 25 is lowered back at the vertical level of inlet conveyor 22, and another block-loaded pallet is transferred from this inlet conveyor 25 to elevating platform 25, and the pallet unloading and block resurfacing process may thus be repeated as desired. Prior art tumbling apparatuses comprise a single drum of large diameter in which a high number of blocks were tumbled together. As this large drum is revolved, the tumbled blocks can be excessively damaged as they are impacted upon with greater energy. The present invention provides a solution for tumbling a similarly high number of blocks simultaneously, while diminishing the occurrence of blocks that become damaged excessively during the tumbling process. Indeed, the tumbling being accomplished in a plurality of smaller distinct drums, the velocity the tumbled blocks can reach within the drum is limited, and the risk that blocks become unusable because they have been too forcefully impacted upon by other blocks is greatly diminished.
Also, with the multiple-drum tumbling apparatus described herein, different batches of blocks, with each batch comprising blocks of different dimensions, can be loaded in distinct drums. The blocks can then be unloaded in a first-in first-out order, thus greatly reducing the amount of manual labour required to sort and regroup blocks of same dimensions after they are tumbled. It is understood that in alternate embodiments of the present invention, any other suitable drive means could be used instead of carousel actuators 69 for actuating the carousels about their corresponding rotation axis. For example, the carousels could be mutually operatively connected so as to rotate integrally together, and a single carousel actuator could drive both carousels simultaneously in a rotary motion.
Also, any other suitable drive means could be used instead of the drive ring
92-belt 96-belt actuator 98 assembly for forcibly revolving the drums about their corresponding rotation axes. For example, each drum could be driven by an independent actuator, or the drums could be driven by the same drive means which drives the carousels in a rotary motion with suitable coupling means.
The present invention also relates to a method for handling concrete blocks and for tumbling the concrete blocks in the above-described tumbling apparatus 60. This method comprises the steps of: a) rotating carousel 62 in order to index drums 86 successively, one at a time, at their drum-loading position; b) loading concrete blocks in each drum 86 when it is indexed at its drum-loading position; c) revolving drums 86 to tumble, and thus resurface the concrete blocks located therein; d) rotating carousel 62 in order to index drums 86 successively at their drum-unloading position; and e) unloading blocks from each drum 86 when it is indexed at its drum-unloading position.
According to the present invention, it is further possible to use alternate tumbling apparatuses to tumble the blocks in distinct batches, with two or more batches being tumbled simultaneously.
One alternate block resurfacing system 200 is partly shown in figures 10 and 11, wherein the following elements similar to those of the first embodiment 20 are used: an inlet conveyor 22, a pallet unload mechanism 24 including an overhead push plate carriage (not shown in figures 10-11), a turntable device 36 and a feed conveyor 40. According to this alternate embodiment of the present invention, block resurfacing system 200 includes a tumbling apparatus 250 including a number of drums, for example four drums 252a, 252b, 252c, 252d, generally referred to as drums 252. Drums 252 are rotatably mounted to a fixed, ground-resting frame (not shown in the schematic views of figures 10-11) so as to be rotatable about respective drum rotation axes. Drums 252 are otherwise stationary, i.e. their axes remain immobile relative to their support frame.
Each drum 252, for example drum 252d, comprises a movable partition 253 at an intermediate portion thereof that divides drum 252d into first and second drum portions 254, 256. Drum 252 also comprises an inlet opening 258 for allowing blocks to be fed into the first drum portion 254 and an outlet opening 260 for allowing blocks to be expelled out of the second drum portion 256. A hopper 262 is fixedly attached to drum 252d at its inlet opening 258, and a drum conveyor 264, which may be for example a belt conveyor, extends between loading device 42 and hopper 262. An outlet door 266 selectively closes outlet opening 260 and in an opened condition it provides access from second drum portion 256 to an outlet conveyor 210 that is shared by all drums 252. Drums 252 are inclined towards outlet conveyor 210.
According to this alternate embodiment of the invention, there is further provided a first loading device 42' including a bench, a reciprocating pushing member and an actuator similar to those of loading device 42 of the first embodiment, with the exception that the loading device bench of first loading device 42' is flat and coplanar with feed conveyor 40 instead of forming a trough. Thus, the pushing member of this loading device 42' is correspondingly sized and configured to push rows of blocks to either side of loading device 42' along this flat bench. Loading device 42' is only shown in figure 10 since it is concealed in figure 11. A second loading device 42" similar to first loading device 42' is further provided downstream of first loading device 42', with the second loading device 42" being only shown in figure 11 since it is removed in figure 10 to allow the underlying portion of outlet conveyor 210 to be illustrated. First loading device 42' is aligned and used in cooperation with the first and second drums 252a, 252b, while second loading device 42" is aligned and used in cooperation with the third and fourth drums 252c, 252d.
In use, a concrete block-loaded pallet is suitably conveyed to inlet conveyor 22, the latter forwarding the pallet to pallet unloading mechanism 24 from where layers of blocks will be dispatched onto feed conveyor 40, as described in the case of the first embodiment of the invention. The blocks will be conveyed by feed conveyor 40 to a selected one of loading device 42' and loading device 42" - for example the rows of blocks may be fed by pairs, one row of block for each loading device 42', 42". Loading device 42', 42" will then move their pushing member from their first to their second limit positions to move the blocks from their benches onto the drum conveyors 264 of a pair of corresponding drums, for example drums 252b, 252d. Each drum conveyor 264 conveys blocks loaded thereon into its corresponding hopper 262 which will redirect the blocks through the drum inlet opening 258 and into the first drum portion 254. Drums 252b, 252d continuously rotating, the blocks therein will be tumbled, and thus resurfaced, within first drum portions 254.
Before another batch of blocks is ready to be fed to drums 252b, 252d by loading devices 42' 42", the movable partitions 253 of drums 252b, 252d will be opened, which will allow the blocks to be biased along the inclined drums 252b, 252d from the first drum portions 254 to the second drum portions 256. The movable partitions 253 are then closed, to allow the first drum portions 254 to be fed with another batch of blocks from loading devices 42', 42" and feed conveyors 264. Meanwhile, the first batch of blocks continues to be tumbled, and consequently resurfaced, within the second drum portion 256. Consequently, two distinct batches of blocks may be tumbled simultaneously although separately within each drum 252.
After a pre-determined tumbling time period, the outlet doors 266 of drums 252b, 252d are opened, and the first batches of blocks corresponding to the two first rows of blocks that were loaded in drums 252b, 252d are expelled out of the second drum portions 256 onto outlet conveyor 210, on which they are conveyed towards a palletizing station (not shown).
Meanwhile, loading devices 42', 42" will feed rows of blocks to drums 252a, 252c that will operate in a similar manner than that described hereinabove for drums 252b, 252d, although the batches of blocks will be resurfaced within drums 252a, 252c in an offset timing relative to those in drums 252b, 252d due to the alternate loading sequences of loading devices 42', 42" that alternately load drums 252b, 252d and drums 252a, 252c.
An alternate loading device could also be provided in block resurfacing system 200, including a single bench, pushing member and actuator assembly longitudinally movable along feed conveyor 40 to alternately load all drums 252a, 252b, 252c, 252d.
Generally, the present invention thus also relates to a block resurfacing system for resurfacing concrete blocks that comprises: a feed conveyor defining a downstream end towards which the blocks are destined to be conveyed. This feed conveyor has been shown as a belt conveyor in the drawings, although it is understood that any suitable type of conveying apparatus would be acceptable. It is understood that the feed conveyor may also extend downstream of the loading device, whereby this conveyor would also act as an outlet conveyor. In such a case, the feed conveyor downstream end is considered to be the portion of the conveyor at which the blocks are fed to the tumbling apparatus; a frame. This frame may be unitary or separated into different frame portions; a tumbling apparatus comprising a number of rotatable drums mounted to the frame and destined to tumble concrete blocks for resurfacing the concrete blocks. This tumbling apparatus will include at least two drums that allow distinct batches of blocks to be separately although simultaneously tumbled. The rotatable drums may be movable, for example if they are installed on a carrousel, or fixed, for example if they are aligned along the feed conveyor; - a loading device adjacent the feed conveyor downstream end, for loading concrete blocks in the drums. Although a bench, pushing member and actuator assembly has been shown in all embodiments, any alternate suitable device capable of loading blocks into the drums is acceptable; indexing means capable of selectively adjusting the relative position of the loading device and the drums for loading concrete blocks in selected ones of the drums according to a predetermined loading sequence. In its simplest version, according to the present invention, the indexing means could include a simple programmed timing of the pushing member of the loading device, whereby two drums located on either side of the pushing member would be alternately loaded with blocks. The blocks would be tumbled within the rotatable drums that would remain otherwise stationary, and expelled before a new batch of blocks is loaded within each of the two drums; and unloading means cooperating with the drums for unloading the drums according to a predetermined unloading sequence. Any suitable type of automatic or controlled unloading device may serve as an unloading means. The invention also relates to a method for batch processing concrete blocks through a tumbling apparatus, the tumbling apparatus comprising a number of rotatable drums, the tumbling apparatus being located adjacent a loading device for loading concrete blocks in the rotatable drums, the method comprising the steps of: a) adjusting the relative position of the drums and the loading device for loading concrete blocks in selected ones of the drums according to a predetermined loading sequence. Thus, the loading device may be movable, the drums may be movable, or the loading device and the drums may be movable; b) loading the concrete blocks in selected ones of the drums according to the predetermined loading sequence, each drum being loaded with one batch of concrete blocks. Each batch of concrete blocks may comprise any pre-determined number of blocks; c) revolving the drums to tumble, and thus resurface, the concrete blocks located therein, the tumbling apparatus having the capacity to tumble a number of batches of blocks simultaneously in separate drums; and d) unloading the drums according to a predetermined unloading sequence.
Thus, one particular advantage brought about by the automated concrete block resurfacing system of the present invention is that it allows batches of blocks to be resurfaced separately, although simultaneously. By controlling the number of blocks fed to each drum of the tumbling apparatus, and by providing pre-determined loading and unloading sequences, the blocks may be expelled from the tumbling apparatus in the order in which they were inserted therein, thus allowing the blocks to be easily sorted after they were tumbled, which may allow the blocks to be re-palletized without requiring any human intervention.

Claims

1. A block resurfacing system comprising a tumbling apparatus and a loading device, said tumbling apparatus comprising:
- a frame; - a carousel rotatably mounted to said frame so as to be rotatable about a carousel rotation axis;
- a number of hollow planetary drums each rotatably mounted to said carousel so as to be rotatable about a corresponding drum rotation axis, and destined to be loaded with concrete blocks by said loading device; - first drive means capable of selectively rotating said carousel about said carousel rotation axis in order to selectively move each said planetary drum between a drum- loading position and a drum-unloading position; and
- second drive means capable of selectively rotating each said planetary drum about said corresponding drum rotation axis; wherein said loading device can be selectively activated for loading concrete blocks in each said drum positioned in said drum-loading position, wherein each said drum can be unloaded when it is positioned in said drum-unloading position, and wherein said second drive means can be activated for tumbling and consequently resurfacing concrete blocks located in said drums.
2. A block resurfacing system according to claim 1, further comprising drum-unloading means for unloading concrete blocks from each said drum positioned in said drum-unloading position.
3. A block resurfacing system according to claim 2, wherein said frame comprises an upright stationary front wall installed adjacent said carousel, and wherein each said drum positioned in said drum-loading position registers with a loading opening made in said front wall, and wherein each said drum positioned in said drum-unloading position registers with a drum-unloading opening made in said front wall.
4. A block resurfacing system according to claim 3, wherein all of said drum rotation axes and said carousel rotation axis are mutually parallel and substantially horizontal.
5. A block resurfacing system according to claim 4, wherein said unloading means comprises a frustoconical shape of each said drum, each said drum thus defining a diametrically smaller end and a diametrically broader end, and wherein said frustoconical shape of each said drum is destined to allow concrete blocks located in each said drum to be continuously gravity-biased towards said diametrically broader end of each said drum.
6. A block resurfacing system according to claim 5, wherein said diametrically broader end of each said drum is open, and said diametrically broader end of each said drum positioned in said drum-unloading position is juxtaposed to said housing unloading opening, for allowing concrete blocks to be unloaded from each said drum positioned in said drum-unloading position by passing through said diametrically broader open end of said drum, through said housing unloading opening and thus out of said tumbling apparatus.
7. A block resurfacing system according to claim 1, wherein said loading device is a block-pushing mechanism.
8. A block resurfacing system, comprising a feed conveyor for conveying concrete blocks towards a first tumbling apparatus and an outlet conveyor for conveying concrete blocks away from said first tumbling apparatus, and further comprising a loading device, said first tumbling apparatus comprising:
- a frame;
- a carousel rotatably mounted to said frame so as to be rotatable about a carousel rotation axis; - a set of hollow planetary drums each rotatably mounted to said carousel so as to be rotatable about a corresponding drum rotation axis, and destined to be loaded with concrete blocks by said loading device; - first drive means capable of selectively rotating said carousel about said carousel rotation axis in order to selectively move each said planetary drum between a drum- loading position and a drum-unloading position; and
- second drive means capable of selectively rotating each said planetary drum about said corresponding drum rotation axis; wherein said feed conveyor can be activated for conveying concrete blocks to said first tumbling apparatus and for engaging them in said loading device, wherein said loading device can be selectively activated for loading concrete blocks in each said drum positioned in said drum-loading position, wherein each said drum can be unloaded when it is positioned in said drum-unloading position, wherein said second drive means can be activated for tumbling concrete blocks located in each said drum, and wherein said outlet conveyor can be activated for conveying concrete blocks away from said first tumbling apparatus after having been unloaded from said set of planetary drums.
9. A block resurfacing system according to claim 8, further comprising a second tumbling apparatus comprising:
- a second frame;
- a second carousel rotatably mounted to said second frame so as to be rotatable about a second carousel rotation axis; - a second set of hollow planetary drums each rotatably mounted to said second carousel so as to be rotatable about a corresponding drum rotation axis, and destined to be loaded with concrete blocks;
- third drive means capable of selectively rotating said second carousel about said second carousel rotation axis in order to selectively move each said drum of said second set of planetary drums between a second drum-loading position and a second drum-unloading position; and
- fourth drive means capable of selectively rotating each said planetary drum of said second set of planetary drums about said corresponding drum rotation axis. wherein each said drum of said second set of planetary drums can be loaded when it is in said second drum-loading position, wherein each said drum of said second set of planetary drums can be unloaded when it is positioned in said second drum-unloading position, and wherein said fourth drive means can be activated for tumbling and consequently resurfacing concrete blocks located in said drums of said second set of planetary drums.
10. A block resurfacing system according to claim 9, wherein said feed conveyor is common to both said first and said second tumbling apparatuses.
11. A block resurfacing system according to claim 9, wherein said loading device is common to both said first and said second tumbling apparatuses.
12. A method for handling concrete blocks and for tumbling the concrete blocks in a tumbling apparatus, said tumbling apparatus comprising a carousel rotatably mounted to a frame, a number of planetary drums each rotatably mounted to said carousel, said tumbling apparatus being located adjacent a loading device for loading concrete blocks in said planetary drums, said method comprising the steps of: rotating said carousel in order to successively index said drums at a drum-loading position; loading concrete blocks in each said drum when it is indexed at said drum-loading position; revolving said drums to tumble, and thus resurface the concrete blocks located therein; rotating said carousel in order to index said drums successively at a drum-unloading position; and - unloading blocks from each said drum when it is indexed at said drum-unloading position.
13. A method for processing concrete blocks according to claim 12, wherein said drums revolve continuously.
14. A method for processing concrete blocks according to claim 12, wherein in step e), said blocks are unloaded from said drums by being expelled therefrom due to the drums being frustoconical in shape, horizontally disposed and rotated about a horizontal axis, the drums having a larger front mouth opening for loading and unloading purposes.
15. A block resurfacing system for resurfacing concrete blocks, comprising: - a feed conveyor defining a downstream end towards which the blocks are destined to be conveyed; a frame; a tumbling apparatus comprising a number of rotatable drums mounted to said frame and destined to tumble concrete blocks for resurfacing the concrete blocks; - a loading device adjacent said feed conveyor downstream end, for loading concrete blocks from said feed conveyor into said drums; indexing means capable of selectively adjusting the relative position of said loading device and said drums for loading concrete blocks in selected ones of said drums according to a predetermined loading sequence; and - unloading means cooperating with said drums for unloading said drums according to a predetermined unloading sequence.
16. A block resurfacing system as defined in claim 15, wherein said loading device comprises a pushing member movable along a bench, and wherein said indexing means and said loading device include a pushing member actuator capable of moving said pushing member between a first position adjacent a first drum and a second position adjacent a second drum, whereby said pushing member is destined to load concrete blocks located on said bench in said first drum when said pushing member is moved from said second position towards said first position, and in said second drum when said pushing member is moved from said first position towards said second position.
17. A block resurfacing system as defined in claim 15, wherein said indexing means comprises a first carousel rotatably mounted to said frame and rotatably carrying a number of said drums, said first carrousel being discretely rotated to allow said drums to be loaded by said loading device according to said predetermined loading sequence, and said first carrousel further being discretely rotated to allow said drums to be unloaded by said unloading means according to said predetermined unloading sequence.
18. A block resurfacing system according to claim 17, wherein said indexing means further comprises a second carousel rotatably mounted to said frame and rotatably carrying a number of additional said drums, said second carrousel being discretely rotated to allow said additional drums to be loaded by said loading device according to said predetermined loading sequence, and said second carrousel further being discretely rotated to allow said additional drums to be unloaded by said unloading means according to said predetermined unloading sequence.
19. A block resurfacing system according to claim 18, wherein said loading device comprises a pushing member movable along a bench, and wherein said indexing means and said loading device include a pushing member actuator capable of moving said pushing member between a first position adjacent a loading position of said first carrousel and a second position adjacent a loading position of said second carrousel, whereby said pushing member is destined to load concrete blocks located on said bench in a drum indexed at said loading position of said first carrousel when said pushing member is moved from said second position towards said first position, and in a drum located at said loading position of said second carrousel when said pushing member is moved from said first position towards said second position.
20. A block resurfacing system according to claim 17, wherein said unloading means includes an inclined inner wall of said drums, with said drums rotating about a generally horizontal axis, said inner wall of each said drum defining a frustoconical shape having a diametrically larger mouth opening and a diametrically smaller end blocked by an end wall, each said drum thus being destined to bias concrete blocks being tumbled therein towards said mouth opening, said unloading means further comprising a retaining wall carried by said frame and closing said mouth openings of said drums, said retaining wall however comprising a loading opening allowing drums to be loaded therethrough according to said predetermined loading sequence and an unloading opening allowing drums to be unloaded therethrough according to said predetermined unloading sequence.
21. A block resurfacing system according to claim 16, wherein said first drum comprises a movable partition therein allowing said first drum to be divided into first and second drum portions for allowing a first and a second batch of concrete blocks to be tumbled separately respectively within said first and second portions of said first drum, said first drum comprising an inlet opening for allowing blocks to be fed into said first drum portion and an outlet opening for allowing blocks to be expelled out of said second drum portion.
22. A method for batch processing concrete blocks through a tumbling apparatus, said tumbling apparatus comprising a number of rotatable drums, said tumbling apparatus being located adjacent a loading device for loading concrete blocks in said rotatable drums, said method comprising the steps of: a) conveying concrete blocks to said loading device; b) adjusting the relative position of said drums and said loading device for loading concrete blocks in selected ones of said drums according to a predetermined loading sequence; c) loading said concrete blocks in selected ones of said drums according to said predetermined loading sequence, each drum being loaded with one batch of concrete blocks; d) revolving said drums to tumble, and thus resurface, the concrete blocks located therein, said tumbling apparatus having the capacity to tumble a number of batches of blocks simultaneously in separate drums; and e) unloading said drums according to a predetermined unloading sequence.
PCT/CA2004/000104 2003-01-28 2004-01-26 Method and apparatus for resurfacing concrete blocks WO2004067242A1 (en)

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