Abstract:
A splitting apparatus comprising a first splitting blade having a smooth top with a width X and a shoulder angle of less than the friction angle, relative to a point in the middle of the top, and a second splitting blade disposed opposite the first splitting blade, the second splitting blade having a smooth top with a width Y and a shoulder angle of less than the friction angle, relative to a point in the middle of the top.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. 61/905,733, filed Nov. 18, 2013, which is hereby incorporated by reference for all purposes as if set forth herein in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to masonry blocks, and more specifically to a masonry block splitting apparatus and method that creates a convex, or “rock-like” split face without the need for projections and the associated cleaning. 
       BACKGROUND OF THE INVENTION 
       [0003]    Block splitting methods and apparatuses typically include splitters with projections to generate split blocks with a roughened look. These projections get fouled easily, and need to be frequently cleaned. 
       SUMMARY OF THE INVENTION 
       [0004]    A splitting apparatus is provided that includes a first splitting blade with a smooth top that forms a blade edge. The smooth top has a width X and a shoulder angle of less than the friction angle from a point in the middle of the top. A second splitting blade is disposed opposite the first splitting blade, and has a smooth top with a width Y and a shoulder angle of less than the friction angle from a point in the middle of the top. 
         [0005]    Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0006]    Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which: 
           [0007]      FIG. 1  is a diagram of a block splitting apparatus for creating a convex split face in accordance with an exemplary embodiment of the present disclosure; 
           [0008]      FIG. 2  is a diagram of a block splitting apparatus loaded with a masonry block, in accordance with an exemplary embodiment of the present disclosure; 
           [0009]      FIG. 3  is a diagram of a block splitting apparatus with a split in a masonry block, in accordance with an exemplary embodiment of the present disclosure; 
           [0010]      FIG. 4  is a diagram of a block splitting apparatus loaded with a split masonry block, in accordance with an exemplary embodiment of the present disclosure; 
           [0011]      FIG. 5  is a diagram of a block splitting apparatus loaded with a split masonry block and retracted splitting blade, in accordance with an exemplary embodiment of the present disclosure; 
           [0012]      FIG. 6  is a diagram of a block splitting apparatus loaded with a masonry block, in accordance with an exemplary embodiment of the present disclosure; 
           [0013]      FIG. 7A  is a diagram of a bottom splitting blade assembly, in accordance with an exemplary embodiment of the present disclosure; 
           [0014]      FIG. 7B  is a diagram of a top splitting blade assembly, in accordance with an exemplary embodiment of the present disclosure; 
           [0015]      FIG. 7C  is a side view of a top splitting blade assembly, in accordance with an exemplary embodiment of the present disclosure; 
           [0016]      FIG. 7D  is a detail view of a bottom splitting blade segment, showing shoulder angle a relative to the peak of a bottom splitting blade segment; 
           [0017]      FIG. 7E  is a detail view showing debris that has accumulated on the infeed edge surface of a bottom splitting blade segment, which is in the process of being wiped by the leading edge of a masonry block; 
           [0018]      FIG. 7F  is a detail view showing debris that has accumulated on the outfeed edge surface of a bottom splitting blade segment, which is in the process of being wiped by the trailing edge of a masonry block; 
           [0019]      FIG. 8  is a flow chart of an algorithm for splitting masonry blocks, in accordance with an exemplary embodiment of the present disclosure; 
           [0020]      FIG. 9  is a force diagram in accordance with an exemplary embodiment of the present disclosure; 
           [0021]      FIG. 10  is a diagram of splitting blade structures in accordance with an exemplary embodiment of the present disclosure; 
           [0022]      FIG. 11A  is a diagram showing an edge texturing configuration prior to the application of pressure, in accordance with an exemplary embodiment of the present disclosure; and 
           [0023]      FIG. 11B  is a diagram showing an edge texturing configuration after the application of pressure, in accordance with an exemplary embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures might not be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness. 
         [0025]      FIG. 1  is a diagram of a block splitting apparatus  100  for creating a convex split face in accordance with an exemplary embodiment of the present disclosure. Apparatus  100  can be used in conjunction with a block handling machine that places an assembly of whole concrete blocks on a conveyor, a conveyor system that moves the whole concrete blocks to a hydraulic press that has been fitted with block splitting blades, a conveyor assembly that moves the split blocks and other suitable equipment. 
         [0026]    Apparatus  100  includes upper splitting blade  104  and lower splitting blade  106 , which can each be formed from one or more of tungsten carbide, hardened AR steel or other suitable materials, and which can each have a smooth surface with no protrusions. Upper splitting blade  104  and lower splitting blade  106  can each have shallow shoulder angles and preferably have shoulder angles that are less than the friction angle. If the shoulder angle is less than the friction angle, then the splitting blade will hold the masonry block in position as it is being split, and will crush the edges of the masonry block to create a convex split face. Conversely, if the shoulder angle is greater than the friction angle, then the masonry block halves will, after the initial fracture, be squeezed away from the splitting blade with little or no split face convexity. 
         [0027]    For most masonry materials, the friction angle is typically 15 to 20 degrees, but if the shoulder angle is less than about 5 degrees, then the debris from splitting operations can impede the subsequent process. In one exemplary embodiment, upper splitting blade  104  can be approximately 30 mm wide with a shoulder angle of approximately 10 degrees, and lower splitting blade  106  can be approximately 50 mm wide with a shoulder angle of approximately 10 degrees, although other widths and shoulder angles can also or alternatively be used. 
         [0028]      FIG. 2  is a diagram of block splitting apparatus  100  loaded with masonry block  102 , in accordance with an exemplary embodiment of the present disclosure. Block  102  is pushed into position by an adjacent block (not explicitly shown). The placement of block  102  can be controlled by an operator, by using optical or mechanical sensors, or in other suitable manners, in order to align splitting blades  104  and  106  with block  102  to a predetermined location. Although splitting blade  106  protrudes slightly from the top surfaces of blade holder  110 , block  102  does not lean towards one side, because it is held in position by the adjacent blocks. 
         [0029]      FIG. 3  is a diagram of block splitting apparatus  100  loaded with a split  202  in masonry block  102 , in accordance with an exemplary embodiment of the present disclosure. When block  102  is in position and upper splitting blade  104  is moved towards lower splitting blade  106 , tension is induced in block  102  along the plane connecting the edges of splitting blades  104  and  106 . A vertical fracture  202  then occurs in block  102 , representing a tension-induced failure of block  102 . 
         [0030]      FIG. 4  is a diagram of block splitting apparatus  100  loaded with split masonry block  102 , in accordance with an exemplary embodiment of the present disclosure. After vertical fracture  202  is formed in masonry block  102 , the angled shoulder surfaces of splitting blades  104  and  106  then cause spalling of the block portions along the intersections of the split plane with the upper and lower surfaces of block  102  to form a convex split face. Although the angled shoulder surfaces of splitting blades  104  and  106  are smooth, the heterogeneous properties of the concrete create an irregular texture similar to that of the original vertical split. 
         [0031]    Once the action of upper splitting blade  104  is completed, the split halves of the masonry block  102  are squeezed away from each other, which stops further spalling to the block portions along the intersections of the split plane with the upper and lower surfaces of block  102 . In addition, some debris can be generated at that time, but the majority of the debris will be held in place by the split halves of masonry block  102 . 
         [0032]      FIG. 5  is a diagram of block splitting apparatus  100  loaded with a split masonry block  102  and retracted upper splitting blade  104 , in accordance with an exemplary embodiment of the present disclosure. The debris formed by the splitting operation is not explicitly shown. 
         [0033]      FIG. 6  is a diagram of block splitting apparatus  100  loaded with masonry block  102 , in accordance with an exemplary embodiment of the present disclosure. After the splitting operation is completed, the split pieces of block  102  are pushed towards outfeed plate  112 , and a new block  102  is moved in behind the split block  102 . As shown in  FIG. 6 , the front block  102  is elevated slightly relative to the rear block  102 , as it rides over lower splitting blade  106 . The sliding movement of the blocks cleans debris from the angled shoulder surfaces of lower splitting blade  106 , as discussed in greater detail below. The surfaces of lower splitting blade  106  are smooth and easily cleaned by this sliding action, which preserves the geometry of the apparatus, without fouling or loading, for consistent results on subsequent splits. 
         [0034]      FIG. 7A  is a diagram of a bottom splitting blade assembly  700 , in accordance with an exemplary embodiment of the present disclosure. Bottom splitting blade assembly  700  includes base plate  734 , which blade support  730  is coupled to, such as with bolts or in other suitable manners. Blade holder  712  is coupled to blade support  730 , such as with bolts or in other suitable manners, and includes a U-shaped channel that holds a plurality of blade segments  706 ,  708  and  710 . Additional blade segments can also or alternatively be provided. In one exemplary embodiment, each blade segment is approximately 2″ wide (W) by 2″ long (L) by 0.5″ high (H), although other suitable configurations can also or alternatively be used. A metal strip  732  formed from brass, aluminum or other soft metal or material, is used to accommodate variations in the dimensional tolerances of each of the blade segments and is also placed within the U-shaped channel. 
         [0035]    The top of each blade segment includes a first flat surface and a second flat surface that meet at a point to form the blade edge. Each flat surface of the top of each blade segment extends downwards at an angle of approximately 10 degrees, although variations within approximately 5 to 15 degrees can also or alternately be used. At each side of the blade segment, the top surface interfaces with a side surface to form an edge, where the edge is typically configured to be flush with the top surfaces of blade holder  712 . Each top surface of blade holder  712  is adjacent with a plate, such as an infeed plate and an outfeed plate, which are used to guide the masonry blocks into position onto bottom splitting blade assembly  700 . The top surfaces of blade holder  712  are configured to bear the load of the masonry blocks during splitting, in order to reduce deflection and wear on the infeed and outfeed plates. 
         [0036]      FIG. 7B  is a diagram of a top splitting blade assembly  750 , in accordance with an exemplary embodiment of the present disclosure. Top splitting blade assembly  750  includes base plate  720 , which blade support  722  is coupled to, such as with bolts  724  or in other suitable manners. Blade  726  is coupled to blade support  722 , such as with bolts  728  or in other suitable manners. In one exemplary embodiment, blade  726  is approximately 30 mm wide by 1000 mm long by 15 mm high, although other suitable configurations can also or alternatively be used. 
         [0037]      FIG. 7C  is a side view of top splitting blade assembly  750 , in accordance with an exemplary embodiment of the present disclosure. 
         [0038]      FIG. 7D  is a detail view of a bottom splitting blade segment  706 , showing shoulder angle a relative to the peak of bottom splitting blade segment  706 . The blade portion of bottom splitting blade segment  706  is elevated above the top surfaces of blade holder  712 , the infeed plate and the outfeed plate. 
         [0039]      FIG. 7E  is a detail view showing debris that has accumulated on the infeed edge surface of bottom splitting blade segment  706 , which is in the process of being wiped by the leading edge of masonry block  102 . As masonry block  102  is pushed forward by the conveyor, the edge of masonry block  102  is pushed up the smooth surface of the infeed edge of bottom splitting blade segment  706 , which wipes the debris from the previous splitting operation away. Although this debris is pushed to the outfeed edge surface of bottom splitting blade segment  706 , the amount of debris from a single splitting operation is relatively small, and is subsequently cleaned as discussed below. 
         [0040]      FIG. 7F  is a detail view showing debris that has accumulated on the outfeed edge surface of bottom splitting blade segment  706 , which is in the process of being wiped by the trailing edge of masonry block  102 . As masonry block  102  is pushed forward by the next masonry block (not shown), the trailing edge of masonry block  102  is pushed down the smooth outfeed edge surface of bottom splitting blade segment  706 , which wipes the debris from the previous splitting operation away. 
         [0041]      FIG. 8  is a flow chart of an algorithm  800  for splitting masonry blocks, in accordance with an exemplary embodiment of the present disclosure. Algorithm  800  can be implemented in hardware, as one or more software systems operating on a programmable controller or in other suitable manners. 
         [0042]    As used herein, “hardware” can include a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field programmable gate array, or other suitable hardware. As used herein, “software” can include one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code or other suitable software structures operating in two or more software applications, on one or more processors (where a processor includes a microcomputer or other suitable controller, memory devices, input-output devices, displays, data input devices such as a keyboard or a mouse, peripherals such as printers and speakers, associated drivers, control cards, power sources, network devices, docking station devices, or other suitable devices operating under control of software systems in conjunction with the processor or other devices), or other suitable software structures. In one exemplary embodiment, software can include one or more lines of code or other suitable software structures operating in a general purpose software application, such as an operating system, and one or more lines of code or other suitable software structures operating in a specific purpose software application. As used herein, the term “couple” and its cognate terms, such as “couples” and “coupled,” can include a physical connection (such as a copper conductor), a virtual connection (such as through randomly assigned memory locations of a data memory device), a logical connection (such as through logical gates of a semiconducting device), other suitable connections, or a suitable combination of such connections. 
         [0043]    Algorithm  800  begins at  802 , where an array of blocks is moved to a conveyor. In one exemplary embodiment, blocks that are manufactured by a block manufacturing process can be stacked on pallets in a layered array, such as an 8×4 array, and a block handling machine can be used to move individual layers of the array to a conveyor system. The block handling machine can include a programmable controller, sensors, hydraulic calipers and other suitable devices that allow the top layer of the array of blocks to be located, to center the calipers on the array, to close the calipers with sufficient pressure to hold the array in place without crushing the individual masonry blocks, and to allow the array to be lifted by a crane and moved to a predetermined location without manual intervention, such as in response to one or more algorithm controls that are provided to the programmable controller (e.g. move calipers to pallet; align calipers; close calipers; raise calipers; move calipers to conveyor). The algorithm then proceeds to  804 . 
         [0044]    At  804 , the array of blocks is aligned to the conveyor, such as by receiving one or more manual alignment commands, by using alignment sensors or in other suitable manners. The algorithm then proceeds to  806 . 
         [0045]    At  806 , a conveyor mechanism is engaged to the rear side surface of the array. In one exemplary embodiment, the conveyor mechanism can include a plurality of motive elements that can be raised through the conveyor surface to engage the rear side surface of the array of blocks, and to apply a lateral force to move the array along the conveyor towards a splitting assembly. The conveyor mechanism can operate under control of a programmable controller in response to manual or sensor inputs, such as in response to one or more algorithm controls that are provided to the programmable controller (e.g. raise motive elements; move motive elements forward until resistance is measured; engage motive elements to force providing device). Likewise, other suitable conveyor mechanisms can also or alternatively be used. The algorithm then proceeds to  808 . 
         [0046]    At  808 , the array of blocks is moved to a first splitting position. In one exemplary embodiment, the dimensions of the array can be used by the programmable controller to determine the first splitting position as a function of the location of the motive elements, sensors can be used to generate signals that are used by the programmable controller to confirm proper alignment of the array of blocks, manual alignment controls can be received at the programmable controller, or other suitable processes can also or alternatively be used. In another exemplary embodiment, the blocks can be textured instead of being split, where the top of the blade is aligned with an intersection between two block faces. The algorithm then proceeds to  810 . 
         [0047]    At  810 , the conveyor mechanism is released, to prevent damage to the mechanism when splitting occurs. In this exemplary embodiment, when the first row of blocks in the array of blocks is split, the block halves will need to be able to move in either direction from the splitting tool when the angled surfaces of the upper blade are buried in the upper surface of the block. Releasing the conveyor mechanism allows this movement to occur during the splitting process without causing damage. The algorithm then proceeds to  812 . 
         [0048]    At  812 , a hydraulic press or other suitable press is activated to split the masonry block and provide additional texturing, such as by using the splitting process discussed herein. In one exemplary embodiment, the programmable controller can receive an instruction to activate the press after sensor data confirming proper alignment has been received, or other suitable processes can also or alternatively be used. The algorithm then proceeds to  814 . 
         [0049]    At  814 , the conveyor mechanism is engaged, such as by coupling the motive elements to a driver or other suitable systems or devices. The algorithm then proceeds to  816 , where the blocks are moved to the next position and the bottom splitting blade is wiped by the movement of the blocks, such as by using a bottom splitting blade that is flush with the conveyor surface and that is not withdrawn between splitting operations. In one exemplary embodiment, the trailing edge of the split block can wipe the outfeed side of the splitting blade, and the leading of the next block to be split can wipe the infeed side of the splitting blade, as discussed herein. The programmable controller can receive an instruction to move the blocks by a predetermined distance or in other suitable manners. The algorithm then proceeds to  818 . 
         [0050]    At  818 , it is determined whether the row of blocks that was split was a last row in an array. If it is determined that there are additional rows in the array to be split, the algorithm returns to  812 , otherwise the algorithm returns to  802 . 
         [0051]    In operation, algorithm  800  allows masonry blocks to be split in a manner that reduces the amount of handling and which simplifies the operation of the splitting process. Algorithm  800  allows a splitting blade such as the one described herein to be used to split block, to provide a textured surface with minimal debris generation and minimal additional cleaning of the splitting blades. 
         [0052]      FIG. 9  is a force diagram in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 9 , the splitting force F is comprised of a normal force N=F*cos Θ and sliding force S=F*sin Θ. Friction force f=μ*N=μ*F*cos Θ opposes sliding force S, and the concrete block slides when S is greater than f. In this exemplary embodiment, Θ=arctan μ. Friction occurs between the block and the blade, where the interface is also filled with pulverized concrete block material. The estimate value for μ for such applications is 0.25 to 0.35. 
         [0053]      FIG. 10  is a diagram of splitting blade structures  1002  through  1012  in accordance with an exemplary embodiment of the present disclosure. Splitting blade structure  1002  has the two-sided structure shown and discussed herein. Spitting blade structure  1004  has a rounded top instead of a point, but otherwise has two flat surfaces that lead up to the rounded top, like splitting blade structure  1002 . Splitting blade structure  1006  has a series of flat surfaces at different angles, where the angles can be less than, equal to or greater than the friction angle, depending on the type of texturing desired. Splitting blade structure  1008  has a rounded profile, where the instantaneous slope of the blade at any point can be less than, equal to or greater than the friction angle, depending on the type of texturing desired. Splitting blade profile  1010  has a rounded base and top transition zone between the flat sides, and splitting blade profile  1012  has a rounded base and sharp top. The common characteristic of splitting blade profiles  1002  through  1012  is the ability of the splitting blades to be cleaned when held stationary in the path of the concrete blocks, because of the smooth surfaces and absence of any protrusions that prevent the splitting blades from being cleaned as the concrete blocks are moved over the splitting blade as the concrete blocks are being split. 
         [0054]      FIG. 11A  is a diagram showing an edge texturing configuration prior to the application of pressure, in accordance with an exemplary embodiment of the present disclosure. In  FIG. 11A , the blade segment  706  is oriented orthogonally to the usual splitting direction, such that the blade is parallel to the direction of travel of blocks  102 A and  102 B, which are adjacent to each other. As blocks  102 A and  102 B are pushed onto blade segment  706 , they are aligned with the blade so as to be balanced at or near the top of the blade, with a space underneath. 
         [0055]      FIG. 11B  is a diagram showing an edge texturing configuration after the application of pressure, in accordance with an exemplary embodiment of the present disclosure. As shown in  FIG. 11B , blocks  102 A and  1028  have been pushed against blade segment  706  and have been crushed, where a layer of debris has formed between blade segment  706  and blocks  102 A and  102 B. In this manner, the edges of blocks  102 A and  102 B can be roughened or textured without the need to split blocks  102 A and  102 B. This roughening or texturing process is advantageous to processes that require the blocks to be tumbled mechanically, which is time consuming and which also results in significant amounts of breakage. 
         [0056]    It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.