Abstract: A turning assembly includes four arms extending from a central position located just outside of the expanse of conveyor rollers, with each of the arms being arranged at 90 degree angles relative to adjacent ones of the four arms. A vertical actuator is configured to move the turning assembly between an active position above a level of the conveyor rollers and an inactive position at or below the level of the conveyor rollers, where at least one of the arms is received within at least one of the gaps between adjacent rollers on the conveyor. Finally, a rotational actuator is configured to rotate the turning assembly arms through an arc around the central position, whereby articles traveling along an article path on the conveyor are configured to either pass over at least one of the turning assembly arms or impact upon the at least one of the turning assembly arms depending upon whether the turning assembly is in an inactive or active position, respectively.

Abstract: A nanobubble-infused liquid is mixed into a dry concrete mix to form an infused wet concrete, where the nanobubble-infused liquid includes a concentration of nanobubbles of a gas at least double a natural concentration of nanobubbles of the gas within a natural state of the liquid. The nanobubble-infused liquid is preferably liquid water infused with a desired concentration of carbon-dioxide (CO2) nanobubbles sized within a certain prescribed range. The infused wet concrete is then transported to the mold of a concrete products forming machine to form a molded product that has enhanced qualities including increased carbon capture within the resulting concrete product, improved curing times, increased flowability, self-healing, and improved release from the product mold.

Abstract: A method for exchanging molds in a concrete products forming machine (CPM) comprises moving a first mold cassette assembly along a linear path to a mold receiving position adjacent to a concrete products forming machine. The first mold is then moved out of the CPM along a mold-transfer path perpendicular to the linear path of the first mold cassette assembly. The first mold is then mounted within the first mold cassette assembly which then moves along the linear path out of the mold-receiving position. The second mold cassette assembly, and pre-mounted second mold, are then moved along the linear path to the mold-extracting position. The second mold is then demounted from the second mold cassette assembly and moved along the mold-transfer path to the concrete products forming machine to effect a mold change within the CPM.

Abstract: A method for moving a mold assembly from a mounted position within a concrete products forming machine includes extending an extraction assembly forwardly from a retracted position at a rear of the concrete products machine to an intermediate position so that terminal ends of the extraction assembly are positioned below a carrying surface of the mold assembly. The extraction assembly is raised at the rear portion of the concrete products machine so that the terminal ends of the extraction assembly contact and raise the carrying surface of the mold assembly up off mold mounting surfaces on the concrete products machine. The extraction assembly is then moved to a fully extended position so that the mold assembly is moved forwardly from the mold mounting surfaces to an operative position whereby the mold assembly can be removed from the extraction assembly and replaced with a replacement mold assembly.

Abstract: On a conveyor for articles traveling from an upstream to a downstream end, an assembly for turning articles is integrated for changing the orientation of the article so that the article may be proper positioned within a stack of such products on a pallet layer. The turning assembly comprises an arm that is selectively extendible along a track to a plurality of extendable positions into an article path on the conveyor. The arm includes an upstream contact surface that is configured to contact a downstream surface of the article off-axis to a center of gravity of the article so that the article rotates about the upstream contact surface to a turned position and continues downstream on the conveyor in the turned position. A turn assist plate pivots into contact with an upstream portion of the article under computer control as needed to assist with turning boxes that are particularly long.

Abstract: An automated mold change system, for use with a concrete products machine of a type having a products forming section and a feedbox assembly section, includes a mold exchange assembly coupled to an underside of the feedbox assembly section and vertically moveable therewith, a mold transfer assembly on an opposed side of the products forming section from the feedbox assembly section, and mounts on the products forming section configured to retain a mold assembly thereon. A mold exchange path runs axially between the mold exchange assembly and the mounts on the products forming section and intersects a mold transfer path of the mold transfer assembly at a load-unload position, wherein the mold exchange assembly is configured to lift a mold off of the mounts and onto the mold transfer assembly at the load-unload position.

Abstract: A pallet feeder assembly for use with a concrete products machine of a type supporting a mold box within a production zone comprises a conveyor having a load/unload expanse configured to be disposed below the production zone, an upstream staging expanse upstream, and upstream and downstream ends. A plurality of sensors operative to detect a presence of a pallet on the conveyor are disposed along a length of the conveyor and include sensors disposed upstream and downstream of the load/unload expanse. Transport means on the conveyor move a pallet loaded on the transport means between the upstream and downstream ends of the conveyor. An open portion within the load/unload expanse is configured to admit a lifting means for raising the pallet from the transport means up into the production zone against an underside of a mold box during a production cycle of a concrete products machine.

Abstract: A mold transfer assembly comprises a carriage assembly configured to be placed adjacent a concrete products forming machine. The carriage assembly has a track running along a mold-transfer path to the mold-receiving path. Each of at the mold cassette assemblies running within the track are configured to retain a mold assembly, wherein the mold cassette assemblies are configured to move along the track between a retracted position spaced from the mold-receiving path adjacent to the concrete products forming machine, and position(s) intersecting the mold-receiving path including an incoming mold cassette position, and an outgoing mold cassette position.

Abstract: A mold assembly for forming concrete products comprising a mold box having cavities for receiving and molding concrete products and a mounting bracket extension coupled to each side wall of the mold box and forming a lower mounting surface of the mold box. Die alignment holes are formed in an underside of each mounting bracket extension and are configured to receive alignment dowels extending upward from shelves of the concrete products forming machine on which the mold box sits. The mounting bracket extensions further include mold transfer locators formed on the underside inward of the die alignment holes so that they are exposed from below when the mold assembly sits on the shelves of the concrete products forming machine. These locators are configured to locate the mold assembly onto mold extractor arms when the mold assembly is lifted off of the alignment dowels by the mold extractor arms during a mold extraction process.

Abstract: A mold extractor assembly for use with a concrete products forming machine of a type having mold mount shelves and a feed box assembly mounted behind the mold mount shelves and moveable in a vertical and horizontal direction to dispense concrete into cavities defined within a mold box mounted on the shelves. The mold extractor assembly comprises a guide rail assembly horizontally oriented along and vertically moveable with the feed box assembly. An extractor arm assembly is moveable along the guide rail assembly in a horizontal direction toward the mold mount shelves. An extractor fork assembly is telescopically nested about the extractor arm assembly and configured to extend a horizontal reach of the mold extractor assembly to beyond the mold mount shelves so that the mold box can be lifted off of the mold mount shelves via the extractor fork assembly and carried forwardly to a mold transfer assembly.

Abstract: A compression shoe for use on a concrete products forming machine comprises a main body and a plated layer overlaid on the main body. The main body is configured to be slidingly received within a mold cavity of a concrete products mold. The plated layer overlaid on the main body of the compression shoe comprises a uniform electroless nickel (Ni), phosphorus (P), and polytetrafluoroethylene (PTFE) nano dispersion coating to effect enhanced material release characteristics by preventing the build-up of material on the compression shoes and enhancing their wear characteristics.

Abstract: A hoist safety lock mechanism includes a pair of pawls formed on terminal ends of each corner of a pallet support structure. The pawls are biased outward to an extended position and include a lower support surface adapted to rest on a support surface. The pawls may be pivotally deflected downward (but not upward) due to impact on a top surface of the pawl. Each pawl is configured to be received within a respective parallel column of slots formed on inwardly-facing sides of the vertical posts forming the lifting frame of the hoist. The slots within each column are vertically offset and separated by separators which can vertically deflect the pawls. Because the slots are vertically offset, and because each terminal end includes a pair of pawls, there is always at least one pawl engaged within the slot even if the other of the pair is deflected by contact with a separator. Thus, any failure of the hoist will cause the pallet support structure to only fall to the next lower separator before the pawl catches it.

Abstract: A flexible pattern-forming palletizing apparatus includes a conveyor having an upstream end for receiving products along a single lane and a downstream end having a plurality of moveable lanes under computer control arrayed along a width of the downstream end. A diverter is positioned between the upstream and downstream end for moving the products from the single lane into selected ones of the plurality of lanes as the products move from the upstream end to the downstream end of the conveyor. A product turner is positioned downstream of the diverter for receiving products positioned in the plurality of lanes and turning selected ones, where the product turner includes turning devices that move between lanes under control of the computer and can be accurately positioned to optimize case turning for a wide array of product.

Abstract: A concrete products forming machine including a main frame, feed drawers, die supports and mold and head assemblies. The feed drawer is moved into position over the mold using an electric belt drive system and includes a vibrating strike off plate to improve surface quality of the molded product, zoned agitators to control movement and placement of concrete, a spring loaded seal system between the walls and floor of the feed box, and quick-release agitator design with urethane sleeves to effect easy and clean removal, replacement and cleaning of the agitators. The concrete products forming machine includes torque tube and leaf spring supports to effect substantially vertical vibrational movement of the mold with air inflatable springs for controlled force between the mold bottom and the pallet. The pallet itself is vibrated from below using phased, counter rotating shafts coupled to the pallet table on which the pallet rests.

Abstract: A concrete products forming machine including a main frame, feed drawers, die supports and mold and head assemblies. The feed drawer is moved into position over the mold using an electric belt drive system and includes a vibrating strike off plate to improve surface quality of the molded product, zoned agitators to control movement and placement of concrete, a spring loaded seal system between the walls and floor of the feed box, and quick-release agitator design with urethane sleeves to effect easy and clean removal, replacement and cleaning of the agitators. The concrete products forming machine includes torque tube and leaf spring supports to effect substantially vertical vibrational movement of the mold with air inflatable springs for controlled force between the mold bottom and the pallet. The pallet itself is vibrated from below using phased, counter rotating shafts coupled to the pallet table on which the pallet rests.

Abstract: A concrete products forming machine including a main frame, feed drawers, die supports and mold and head assemblies. The feed drawer is moved into position over the mold using an electric belt drive system and includes a vibrating strike off plate to improve surface quality of the molded product, zoned agitators to control movement and placement of concrete, a spring loaded seal system between the walls and floor of the feed box, and quick-release agitator design with urethane sleeves to effect easy and clean removal, replacement and cleaning of the agitators. The concrete products forming machine includes torque tube and leaf spring supports to effect substantially vertical vibrational movement of the mold with air inflatable springs for controlled force between the mold bottom and the pallet. The pallet itself is vibrated from below using phased, counter rotating shafts coupled to the pallet table on which the pallet rests.

Abstract: A mold for concrete products includes a grid with a plurality of cavities that are open to both sides of the grid. The grid is bonded with polyurethane about its perimeter to the inner perimeter of a frame having a central opening therein. The grid may be formed of a single unitary piece or it may be formed from a plurality of sub-grids that are each bonded to the other with polyurethane.

Abstract: A tumbler for tumbling concrete products comprises a rotatable cylindrical drum having an input end that is slightly elevated relative to an output end. Tire retread strips are placed side-by-side on the radially inner surface of the drum and extend along its length. Clamps having lateral arms extending on either side are engaged with lateral tread grooves on the strips. The clamps are bolted to the drum between adjacent strips thereby securing the strips to the radially inner surface of the drum.

Abstract: A concrete products forming machine including a main frame, feed drawers, die supports and mold and head assemblies. The feed drawer is moved into position over the mold using an electric belt drive system and includes a vibrating strike off plate to improve surface quality of the molded product, zoned agitators to control movement and placement of concrete, a spring loaded seal system between the walls and floor of the feed box, and quick-release agitator design with urethane sleeves to effect easy and clean removal, replacement and cleaning of the agitators. The concrete products forming machine includes torque tube and leaf spring supports to effect substantially vertical vibrational movement of the mold with air inflatable springs for controlled force between the mold bottom and the pallet. The pallet itself is vibrated from below using phased, counter rotating shafts coupled to the pallet table on which the pallet rests.

Abstract: A tumbler for tumbling concrete products comprises a rotatable cylindrical drum having an input end that is slightly elevated relative to an output end. Tire retread strips are placed side-by-side on the radially inner surface of the drum and extend along its length. Clamps having lateral arms extending on either side are engaged with lateral tread grooves on the strips. The clamps are bolted to the drum between adjacent strips thereby securing the strips to the radially inner surface of the drum.