A rapidly deployable building 3D printer

Abstract

The application discloses a rapidly deployable building 3D printer, which comprises a self-walking system, a rotary arm system, a feeding system, a high-precision nozzle system and a control system, wherein the control system comprises a man-machine interactive interface; the self-walking system and the rotary arm system can be realized after modification on the basis of a truck crane or a caterpillar crane; the high-precision nozzle system is installed at the distal end of the rotary arm; the feeding system is composed of a spiral pump and slurry conveying hoses arranged along the arm; the feeding system conveys slurry along the arm to the high-precision nozzle; the control system performs coordinate system conversion on a printing model, automatically controls the stretching, pitching and rotating of the arm according to the coordinate system position of each printing point, and automatically controls the rotating extrusion speed of the spiral pump. Since the self-walking system, the rotary arm system, the high-precision nozzle system, the feeding system and the control system are an integral whole, no installation is needed before printing construction, only leveling in the horizontal direction is needed, the construction preparation time is short, and the rapidly deployable building 3D printer can be rapidly deployed.

Description

Technical Field

[0001] This invention belongs to the field of intelligent construction in civil engineering, specifically a 3D printer for building construction that uses industrial robots to repeatedly lay material layers to construct free-form building structures. Background Technology

[0002] Currently, 3D printing technology for construction, as an emerging construction method, offers advantages such as material savings, shorter construction periods, and reduced labor costs. However, existing 3D printing machines require the construction of a three-axis (X, Y, Z) frame system consisting of a base, columns, and beams around the proposed structure. Levels and measuring tools are then used to check the flatness of the base and the verticality of the columns to ensure the horizontality and verticality of the beams meet design requirements. Disassembling and assembling the frame alone can take one to two days, and even longer for complex structures with many components. If multiple building units need to be printed on-site, the process of repeatedly installing, printing, disassembling, transporting components, and reinstalling becomes cyclical and repetitive, making it difficult to meet the demands for high efficiency and rapid deployment. Therefore, this invention aims to provide a novel 3D printing machine for construction and its innovative structure to solve the aforementioned problems. Summary of the Invention

[0003] To overcome the shortcomings of existing technologies, this invention proposes a rapidly deployable architectural 3D printer.

[0004] The technical solution adopted by this invention to solve its technical problem is as follows: A rapidly deployable architectural 3D printer, comprising a self-propelled system, a rotary boom system, a feeding system, a high-precision nozzle system, and a control system. The control system includes a human-machine interface. The functions of the self-propelled system and the rotary boom system can be achieved by modifying a truck crane or crawler crane. A high-precision nozzle system is installed at the far end of the rotary boom. The feeding system consists of a screw pump and a slurry delivery hose arranged along the boom. The feeding system delivers slurry along the boom to the high-precision nozzle. After performing coordinate system transformation on the printed model, the control system automatically controls the extension, tilt, and rotation of the boom according to the coordinate system position of each printing point, while automatically controlling the rotational extrusion speed of the screw pump.

[0005] The high-precision nozzle system has a detachable nozzle head, and nozzle heads of different diameters can be installed according to the flatness requirements of the surface of the building to be printed and the material flow characteristics of different slurries.

[0006] The control system transforms the printed model from the original three-dimensional Cartesian coordinate system to a transformed spherical coordinate system. The correspondence between the two is as follows:

[0007]

[0008]

[0009]

[0010] Where: r represents the distance from the origin to point P, θ represents the angle between the line connecting the origin to point P and the positive z-axis (zenith angle), and φ represents the angle between the projection of the line connecting the origin to point P onto the xOy plane and the positive x-axis (azimuth angle).

[0011] The control system transmits the r value to the slewing boom system to control the telescopic boom length, transmits the θ value to the slewing boom system to control the vertical pitch angle of the boom, and transmits the φ value to the slewing boom system to control the horizontal rotation angle of the boom.

[0012] The control system controls the slewing boom system to rotate horizontally at a fixed angle θ each time, while simultaneously controlling the extension and retraction of the boom according to the value r. After printing the inclined surface at the angle θ, the control system raises the boom by Δθ, and then rotates horizontally and extends and retracts the boom again, repeating this process. In other words, the control system controls the slewing boom system to print in layers with an inclined surface at a Δθ chamfer.

[0013] The control system simultaneously and automatically controls the rotational extrusion speed of the screw pump, causing the nozzle head to discharge slurry at a speed of Q=D*K*△T, where: Q is the slurry discharge rate per second at point P, D is the diameter of the installed nozzle head, K is the slurry constant, which is the maximum extrusion rate per second per unit diameter determined by the material properties of the slurry, D*K is the maximum slurry discharge rate per second on the same horizontal plane, and △T is the position coefficient, which is a variable less than or equal to 1. The value of △T is proportional to the value of r * sin(θ) * cos(φ). Its purpose is to form a flat printing inclined surface by controlling the slurry discharge rate at each point on the △θ chamfered inclined surface.

[0014] During the printing process, the construction personnel can change the value of coefficient K through the human-machine interface of the control system. The control system obtains a new slurry constant K'. After completing a flat θ-angle printing inclined surface, when starting to print a new △θ-angle inclined surface, the initial extrusion speed of the spiral pump on the inclined surface is adjusted so that the nozzle head discharges slurry at a speed of Q=D*K'*△T.

[0015] The beneficial effects of this invention are as follows:

[0016] 1. The present invention provides a rapidly deployable architectural 3D printer, in which the self-propelled system, rotating boom system, high-precision nozzle system, material feeding system, and control system are integrated into one unit. It does not require installation before printing and only needs to be leveled in the horizontal direction, resulting in short construction preparation time and rapid deployment.

[0017] 2. The building 3D printer described in this invention can be quickly deployed and can be quickly removed after completing the printing of a single unit without dismantling.

[0018] 3. The rapid deployment building 3D printer described in this invention allows construction personnel to drive it to a new location and use it directly for continuous printing of multiple building units, eliminating the complicated operations such as dismantling, component transfer, and reinstallation required by existing building 3D printers.

[0019] 4. The rapidly deployable architectural 3D printer described in this invention uses an inclined surface with a △θ chamfer for layered printing, eliminating the obstruction of the crane arm by the rectangular height of the building. Attached Figure Description

[0020] The invention will now be further described with reference to the accompanying drawings.

[0021] Figure 1 This is a schematic diagram of layered printing using a △θ chamfered inclined surface.

[0022] Figure 2 This is a schematic diagram of layered printing using a conventional horizontal plane. Detailed Implementation

[0023] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0024] The technical solution adopted by this invention to solve its technical problem is as follows: A rapidly deployable architectural 3D printer, comprising a self-propelled system, a rotary boom system, a feeding system, a high-precision nozzle system, and a control system. The control system includes a human-machine interface. The functions of the self-propelled system and the rotary boom system can be achieved by modifying a truck crane or crawler crane. A high-precision nozzle system is installed at the far end of the rotary boom. The feeding system consists of a screw pump and a slurry delivery hose arranged along the boom. The feeding system delivers slurry along the boom to the high-precision nozzle. After performing coordinate system transformation on the printed model, the control system automatically controls the extension, tilt, and rotation of the boom according to the coordinate system position of each printing point, while automatically controlling the rotational extrusion speed of the screw pump.

[0025] The aforementioned rapidly deployable architectural 3D printer integrates a self-propelled system, a rotating boom system, a high-precision nozzle system, a material feeding system, and a control system into a single unit, requiring no installation before printing.

[0026] The construction workers operate the self-propelled system of the 3D building printer to drive it to the construction position. The construction position should be lower than the outdoor ground level of the building being printed, so that the rotation center of the slewing boom is basically at the same height as the outdoor ground level of the building being printed. After the 3D building printer is in place, the four hydraulic support legs are lowered and adjusted. The level is then observed using a level instrument to ensure that the 3D building printer is in a horizontal state.

[0027] If the slewing boom system is further optimized so that the slewing boom can tilt downwards in the vertical plane and make a negative angle below the horizontal line, then the working position of the building 3D printer can be at the same height as the outdoor ground of the building being printed.

[0028] Construction workers connected the continuous pulping machine to the screw pump of the building 3D printer's feeding system and checked its working status.

[0029] Check the required printing materials, such as high-performance concrete, geopolymer concrete, and fiber-reinforced materials, and ensure that their quality and quantity meet the printing requirements to complete the construction preparation work.

[0030] The 3D model is converted into G-code using specialized slicing software. The G-code file is then imported into the control system of the 3D building printer. The control system transforms the original 3D Cartesian coordinate system used to draw the 3D building model into a transformed spherical coordinate system. The correspondence between the two systems is as follows:

[0031]

[0032]

[0033]

[0034] Where: r represents the distance from the origin to point P, θ represents the angle between the line connecting the origin to point P and the positive z-axis (zenith angle), and φ represents the angle between the projection of the line connecting the origin to point P onto the xOy plane and the positive x-axis (azimuth angle).

[0035] The control system performs secondary slicing of the three-dimensional model with an inclined surface at a △θ chamfer, and displays a layered schematic diagram of the sliced ​​model with the inclined surface at a △θ chamfer on the human-computer interaction display.

[0036] Construction personnel select the nozzle diameter value D through the human-machine interface of the control system, and input the slurry constant K according to the material flow characteristics of different slurries. The value of K can also be determined after on-site printing and testing.

[0037] Then, the printing start switches of the continuous pulping machine and the architectural 3D printer are turned on. The control system controls the rotary boom system to rotate horizontally at a fixed angle θ each time, while controlling the extension and retraction of the boom according to the r value. After printing the inclined surface at the angle θ, the control system raises the boom system by △θ, and then rotates horizontally and extends and retracts the boom again, and repeats this process. That is, the control system controls the rotary boom system to print in layers with an inclined surface with a △θ chamfer.

[0038] like Figure 1 As shown, after the architectural 3D printer prints the inclined surface at angle θ, it prints layers of inclined surfaces raised by angle △θ each time. This eliminates the obstruction of the crane arm by the rectangular height of the building. Figure 2 As shown, if conventional horizontal plane is used for layer printing, when printing the fourth layer, the extension of the boom will be blocked by the third layer structure that has been printed.

[0039] The control system simultaneously and automatically controls the rotational extrusion speed of the screw pump, causing the nozzle head to discharge slurry at a speed of Q=D*K*△T, where: Q is the slurry discharge rate per second at point P, D is the diameter of the installed nozzle head, K is the slurry constant, which is the maximum extrusion rate per second per unit diameter determined by the material properties of the slurry, D*K is the maximum slurry discharge rate per second on the same horizontal plane, and △T is the position coefficient, which is a variable less than or equal to 1. The value of △T is proportional to the value of r * sin(θ) * cos(φ). Its purpose is to form a flat printing inclined surface by controlling the slurry discharge rate at each point on the △θ chamfered inclined surface.

[0040] During printing, the control system displays printing parameters such as layer height, printing speed, and extrusion volume in real time on the human-machine interface display.

[0041] During the printing process, the operator can change the coefficient K through the human-machine interface of the control system. The control system then obtains a new slurry constant K'. After completing a smooth θ-angled printing surface, when starting to print a new △θ-angled surface, the initial extrusion speed of the spiral pump on that surface is adjusted so that the nozzle head discharges slurry at a speed of Q=D*K'*△T. The high-precision nozzle system automatically adjusts the slurry discharge speed according to the signal given by the control system.

[0042] Meanwhile, during the printing process, construction workers can add reinforcing bars, beams, and other structural reinforcements at appropriate locations according to design requirements to improve the strength and stability of the building.

[0043] After printing is complete, disconnect the connection between the continuous pulping machine and the spiral pump of the building 3D printer's feeding system. After cleaning the pulp delivery hose and high-precision nozzle, you can drive the building 3D printer to the next printing station and repeat the above operation process to complete the printing of multiple units.

[0044] In the construction of large-scale resort and amusement projects, there are a large number of complex-shaped, low-height buildings and structures. The rapid-deployment building 3D printer described in this invention allows construction workers to drive it to a new location and use it directly for continuous printing of multiple building units. This eliminates the complicated operations required by existing building 3D printers, such as dismantling, component transportation, and reinstallation, greatly improving construction efficiency and shortening the construction period.

Claims

1. A printing method for a rapidly deployable architectural 3D printer, comprising a self-propelled system, a rotary boom system, a feeding system, a high-precision nozzle system, and a control system, characterized in that, A high-precision nozzle system is installed at the far end of the slewing boom. The feeding system consists of a screw pump and a slurry delivery hose arranged along the boom. The feeding system delivers the slurry along the boom to the high-precision nozzle. The control system performs coordinate system transformation on the printed model and automatically controls the extension, tilt, and rotation of the boom according to the coordinate system position of each printing point. At the same time, it automatically controls the rotational extrusion speed of the screw pump. The control system transforms the printed model from the original three-dimensional Cartesian coordinate system to a transformed spherical coordinate system. The correspondence between the two is as follows: Where: r represents the distance from the origin to point P, and θ represents the angle between the line connecting the origin to point P and the positive z-axis. φ represents the angle between the projection of the line connecting the origin to point P onto the xOy plane and the positive x-axis; The control system transmits the r value to the slewing boom system to control the telescopic boom length, transmits the θ value to the slewing boom system to control the vertical pitch angle of the boom, and transmits the φ value to the slewing boom system to control the horizontal rotation angle of the boom. The control system controls the slewing boom system to rotate horizontally at a fixed angle θ each time, while controlling the extension and retraction of the boom according to the r value. After printing the inclined surface at the angle θ, the control system raises the boom system by Δθ, and then rotates horizontally and extends and retracts the boom again, and repeats this process. In other words, the control system controls the slewing boom system to print in layers with an inclined surface at a Δθ chamfer.

2. The printing method of a rapidly deployable architectural 3D printer according to claim 1, characterized in that, The control system simultaneously and automatically controls the rotational extrusion speed of the screw pump, causing the nozzle head to discharge slurry at a speed of Q=D*K*△T, where: Q is the slurry discharge rate per second at point P, D is the diameter of the installed nozzle head, K is the slurry constant, which is the maximum extrusion rate per second per unit diameter determined by the material properties of the slurry, D*K is the maximum slurry discharge rate per second on the same horizontal plane, and △T is the position coefficient, a variable less than or equal to 1. The value of △T is proportional to the value of r*sin(θ)*cos(φ). By controlling the slurry discharge rate at each point on the △θ chamfered inclined surface, a flat printing inclined surface is formed.

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