Modularized assembly type intelligent construction method for 3D printing space special-shaped reinforced wall

Abstract

The invention discloses a modular assembly type intelligent building method for a 3D printing space special-shaped reinforced wall, and belongs to the technical field of civil construction. The 3D printing space special-shaped reinforced wall modular assembly type intelligent construction method comprises the following steps that a special-shaped wall is manufactured through 3D printing, and the space special-shaped wall serves as a module unit to be assembled to form a building body. According to the method, intelligent additive construction of a space structure is achieved through digital design 3D printing special-shaped wall module die-free construction and industrial assembly, compared with a traditional building, the method can adapt to special-shaped space body type design, die-free manufacturing integrated digital forming and high-efficiency modular industrial assembly, the complicated repairing and assembling procedure of traditional construction is omitted, and the construction efficiency is improved. The system has the remarkable advantages of high precision, high efficiency, few procedures, low emission, high energy conservation and low cost, can adapt to the unfavorable situation of shortage of construction workers in China, and improves the digital and intelligent level of the construction industry.

Description

Technical Field

[0001] The present invention belongs to the technical field of civil construction, and in particular relates to a modular assembly intelligent construction method for a 3D printed spatial special-shaped reinforced wall. Background Art

[0002] Traditional construction involves a lot of wet work, requires formwork, is expensive, is easily affected by the environment, is inefficient, and has uneven quality. The digital design and intelligent construction of 3D printed civil engineering projects can be constructed without formwork, mechanically operated, and use digital construction and additive manufacturing to achieve mechanized and automated construction, highlighting the strong technical advantages. Existing 3D printed concrete materials are already relatively mature. For example, Chinese patents with publication numbers CN201910134165, CN201810913908, and CN201910133642 propose mix ratio designs for 3D printed concrete. The corresponding technical standards "Technical Regulations for 3D Printing of Concrete", "Test Methods for Basic Mechanical Properties of 3D Printed Concrete", and "Test Methods for Performance of 3D Printed Concrete Mixtures" have been promulgated. Existing 3D printing concrete engineering applications are mainly landscape buildings and small temporary buildings made of plain concrete. It is difficult to carry out industrial reinforcement following CNC printing assembly, and it is impossible to form reinforced concrete structures according to the requirements of existing structural specifications, and meet the service safety requirements of buildings under various load conditions. This is the biggest technical obstacle to the application of 3D printing technology in engineering construction at this stage. Although technical means such as prefabricated reinforcement CN202011572733.4, inserted reinforcement, laid reinforcement and wire mesh reinforcement have been proposed at this stage, how to carry out integrated digital design of architecture, structure and decoration for spatial structures, especially how to carry out spatial modular decomposition and assembly reinforcement for 3D printed building structures, integrate with existing structural design methods and standards, and uniformly realize digital industrial modular rapid construction, is still a technical problem that needs to be solved at this stage.

[0003] Prefabricated buildings are an important trend in the development of modern building industrialization. They have the characteristics of fast construction speed, high construction efficiency, short construction period, and high degree of industrialization. They are the strategic development direction of the country's current transformation of the construction industry to adapt to the aging of construction workers, improve the speed and accuracy of construction, and carry out industrialization transformation of the construction industry. However, the number of connection nodes of ordinary prefabricated building components (CN214195057U) is large, resulting in complex construction (CN2023103 96598), large amount of manual operation, high difficulty, low efficiency, and poor integrity. For example, the connection between columns is mostly made by mechanical sleeve connection, bolt connection, and welding, which have technical deficiencies such as high connection accuracy requirements, many operation procedures, and difficult to ensure connection quality. Modular prefabricated buildings are a new type of construction method that conforms to the industrialization of modern buildings. The integrated design of decoration, water, electricity, heating and other functions forms a component module and assembles it on site to form a structure, which can reduce the number of nodes, improve integrity, and achieve rapid industrialized construction. However, the module body design and vertical and horizontal connections are the key to this structural system. At present, the housing construction system with simple manufacturing process and mechanical properties that meet the design requirements mostly adopts steel plate frames (CN202210236563) and wire mesh to realize modular unit production, which has the technical limitations of insufficient adaptability to plane modeling and time-consuming and labor-intensive material processing. Summary of the invention

[0004] The purpose of the present invention is to provide a modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls, which is suitable for intelligent construction in various construction environments and can accurately, quickly and efficiently realize the industrialized mold-free production and assembly construction of various complex spatial shapes.

[0005] The technical solution provided by the present invention is: a modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls. The method first removes the limitations of the existing building body's plane right-angle shape based on a digital space design method, and then uses 3D printing technology to design and manufacture special-shaped wall modules according to the building's functions and structural bearing service requirements. Finally, the module rigid connection design and assembly construction process optimization are carried out based on digital simulation of the space model.

[0006] A modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls, the specific steps are as follows: S1, based on the demand for space shape in personalized design, uses artificial intelligence technologies such as digital association, image search and synthesis to generate architectural renderings, imports spatial modeling software based on contour / perspective recognition and digital simulation technology, and conducts detailed design according to architectural space and structural functions; S2, divide the digital model of the building space into blocks in layers along the height direction according to the scale, shape, and construction process, and perform functional refinement and design optimization according to the spatial distribution of each layer of blocks; S3, divide the wall modules according to the layout, function and size of each block, taking into account the lifting parameters and assembly process, and carry out spatial wall structure design in combination with decoration, assembly and load-bearing requirements; S4, carry out detailed structural design of wall module splicing, combine the mix design of 3D printing materials, filling functional materials and cast-in-place materials after assembly and the three-dimensional simulation evolution of the assembly process to ensure the smooth realization of the construction of integrated intelligent physical buildings.

[0007] Among them, the requirements can be geometric shapes, architectural concepts, or spatial entities. The architectural effect is determined based on artificial intelligence digital design, and the corresponding spatial structure layout is clarified. The building shape can have different widths, heights and span ranges, and can be divided along the height direction according to the structural function and body size according to the 3D printing stacking molding process. The block design improves and optimizes the surface morphology and geometric shape according to the functions and designs of buildings at different heights. The wall modules are divided according to different printing materials, different assembly and lifting equipment, and the overall building load-bearing and functional requirements, and wall material design, wall hollow cavity design, wall printing reinforcement design and wall assembly structure design are carried out.

[0008] Furthermore, the special-shaped wall is formed by a combination of 3D printing materials, functional filling materials, and assembled cast-in-place materials and space shapes.

[0009] Furthermore, the 3D printing material includes modified components and composite reinforcement components of cement-based materials, geopolymer materials, gypsum materials, resin materials, plastics, and nylon materials. The 3D printing material also uses one or more of industrial waste residues, construction solid waste, and natural building materials as aggregates or admixtures. The modified components include one or more of thermal insulation, waterproofing, density adjustment, and coagulation adjustment; the special-shaped wall adopts one or more of solid, foam, or hollow microsphere types.

[0010] Furthermore, existing building reinforcement materials, such as steel bars, FRP bars, composite material bars and other types of bars are used for structural reinforcement.

[0011] In summary, this application has at least the following advantages: 1. The digital design 3D printing of special-shaped wall modules is adopted to realize the additive intelligent construction of spatial structures by form-free construction and industrial assembly. Compared with traditional buildings, it can adapt to the design of special-shaped space shapes, integrated digital molding of form-free manufacturing, and high-efficiency modular industrial assembly, eliminating the complicated repair and installation procedures of traditional construction. It has the significant advantages of high precision, high efficiency, fewer procedures, low emissions, high energy saving, and low cost. At the same time, it can adapt to the unfavorable situation of shortage of construction workers in my country and improve the digitalization and intelligence level of the construction industry; 2. In view of the existing 3D printing technology, make full use of its complex spatial modeling capabilities to design spatial special-shaped wall modules, take into account the structural requirements and load-bearing needs of the structure to preset special-shaped cavity segments, realize the rigid connection of special-shaped wall module segments through connecting bars and pin bars, realize the hidden structural columns and ring beams in the outer mold of the special-shaped wall through printing technology, establish a technical method for spatial reinforcement that meets the existing structural design standards, use the three-dimensional digital model of the wall to evolve the construction process to avoid spatial collisions, and realize the spatial rigid connection of spatial segments. At the same time, consider the high-efficiency promotion and development model of prefabricated buildings, and explore new building design and construction processes. This is a key technology for the development of digital intelligent construction;

[0012] 3. The modular assembly intelligent construction method of 3D printed spatial special-shaped walls is adopted, wherein the 3D printing materials include modified components and composite reinforcement components of cement-based materials, geopolymer materials, gypsum materials, resin materials, plastics, and nylon materials. The 3D printing materials also use one or more of industrial waste residues, construction solid waste, and natural building materials as aggregates or admixtures. The modified components include one or more of heat preservation, waterproofing, density adjustment, and condensation adjustment. The special-shaped walls use one or more of solid, foam, or hollow microsphere types, which has the advantages of strong applicability, local materials, low carbon, and environmental protection.

[0013] 4. By adopting the 3D printing spatial special-shaped wall modular assembly intelligent construction method, existing building reinforcement materials, such as steel bars, FRP bars, composite material bars and other types of reinforcement materials, can be used to reinforce the printed modules and achieve effective rigid connection, forming a strong and safe overall structure with outstanding advantages of earthquake resistance and disaster resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is the technical framework diagram of this application; Figure 2 It is an architectural rendering; Figure 3 It is a structural space figure; Figure 4 It is a digital information map of structural space; Figure 5 It is a zoning plan design; Figure 6 yes Figure 5 The planning and design drawings of the middle and bottom blocks; Figure 7 It is a schematic diagram of the overall structure of the special-shaped wall; Figure 8 yes Figure 7 Schematic diagram of the top view structure.

[0015] In the figure: 1. Wall No. 1; 2. Pin reinforcement; 3. Hook; 4. Stirrups; 5. Longitudinal reinforcement; 6. Wall No. 2; 7. Longitudinal reinforcement; 8. Wall No. 3; 10. Wall No. 4; 11. I-type; 12. T-type; 13. L-type. Implementation

[0016] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific implementation methods described herein are only used to explain the present invention and do not limit the protection scope of the present invention.

[0017] The present application discloses a modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls. The method generates architectural renderings based on arbitrary forms and based on personalized design requirements using artificial intelligence technology, establishes spatial models based on contour recognition, perspective principles and digital simulation technology, and performs detailed design according to architectural space and structural functions; improves the spatial structure entity information model according to architectural functional requirements and architectural structure design standards, and performs body zoning design on buildings according to the scale of buildings. Medium-sized and large buildings can be designed in ground floor, middle floor and high-rise blocks, and small buildings can be designed only in ground floor and high-rise blocks; the ground floor building blocks mainly consider the connection structure between the structure and the foundation, water, electricity, heating and ventilation requirements, and the lighting and traffic requirements of doors and windows for refined design; the middle floor blocks mainly consider the printing accuracy, architectural decoration requirements and production process for artistic design; the high-rise blocks mainly consider the ventilation requirements, clearance requirements, and connection with the upper structure for design.

[0018] The design of each wall module must take into account the environment and structural defense level, building durability requirements, and functional differences such as exterior / interior walls, living rooms / bedrooms, etc. to carry out printing material design, wall space design, and insulation material filling design. At the same time, each wall module needs to use 3D printing materials, functional filling materials, and post-assembly cast-in-place technology and industrial reinforcement technology through effective space module connection technology to organically combine the building structure's seismic structure, structural bearing requirements, and construction and installation, and achieve integrated intelligent construction.

[0019] Now, combined with the traditional architectural space plane building residential structure, the modular assembly intelligent construction method of 3D printing space special-shaped reinforced wall is demonstrated in detail. It should be noted that the structure is only a simple shape to more intuitively demonstrate the technical steps. More complex spatial structures can also be designed, implemented and constructed according to the same method and steps.

[0020] like Figure 1As shown in the figure, firstly, according to user needs, the architectural renderings are generated with reference to the traditional residential architectural style, the architectural outline is obtained by using image processing technology, the size parameters and relative coordinates of the structural space are calculated according to the grayscale and color characteristics and perspective principles, and the spatial digital information is formed by using the computer vision processing method Open CV, which is imported into the spatial modeling software, such as 3DsMax, Revit, Sketchup, Rhino, etc., and the detailed design is carried out according to the architectural space and structural functions, such as Figure 2-4 As shown, a physical digital model of an ordinary residential building is displayed.

[0021] like Figure 5 As shown, the building is then divided into two areas for body design. The residential space is built in a small scale, so it is divided into the ground floor (gray) and high-rise (white) blocks for further detailed design.

[0022] Door and window openings are opened on the ground floor taking into account traffic and lighting functions. At the same time, water supply, power supply, heating, communication and other goals are carried out in accordance with personalized user needs and traditional building standards. The digital wall module is combined to set up pipes and lines in the cavity, and printing path design and printing process optimization are carried out.

[0023] In addition to this demand, the bottom wall modules need to be structurally connected with the foundation and high-rise wall modules, and the cavity should be designed considering different specific requirements such as hoisting and insulation. The printing and intelligent construction can be realized in stages by using stage filling and cast-in-place after assembly.

[0024] like Figure 6 As shown in the figure, since the entire building is designed in different areas along the height, when the building scale and space area are large, it is necessary to divide the wall modules within the block. The main basis for division is intelligent construction and assembly parameters such as transportation weight, hoisting weight, material curing time and printing parallel efficiency. The residential project of this project considers the weight limit of ordinary highway freight, the load of ordinary cranes and the printing efficiency of 3D printed concrete, and divides the bottom block of the space wall into 18 special-shaped modules for further refinement. The module connection along the height direction is achieved by inserting steel bars through the cavity of the special-shaped space wall, and the rigid connection is achieved by forming an overall structure through the post-cast wall filling material.

[0025] The design of each wall module must take into account the environment and structural defense level, building durability requirements, and distinguish between exterior / interior walls, living rooms / bedrooms, etc. to carry out printing material design, wall space design, and functional material filling design such as insulation / sound insulation. Taking the typical corner side wall module in the bottom block as an example, the structural space design and connection design method of 3D printing space reinforced wall module are discussed in detail.

[0026] During the wall printing process according to the building area and functional requirements, steel bars are laid in the high stress area of ​​the stress distribution cloud map according to the computer numerical simulation analysis of the spatial structure, and the steel bars protruding from the foundation are spatially interspersed in the cavity of the special-shaped printed wall in combination with the requirements of the building structure construction. Rigid connection is achieved during assembly by burying connectors such as buckles and rings, and the cast-in-place materials are integrated after assembly to form a spatial integral building. Based on the three-dimensional digital model, the printing path optimization, printing / reinforcement process coordination and spatial collision simulation are carried out. Using an integrated digital design model, material design, structural cavity design, insulation and sound insulation and other functional material filling, reinforcement reinforcement and module splicing are integrated to form a high-efficiency and simple assembly intelligent construction technology to meet the requirements of structural load-bearing safety and service comfort.

[0027] For example, in this project, in view of the residential environment in the north, half of the wall cavity is pre-filled with thermal insulation solid waste concrete, the cavity at the hook position is pre-filled with high-strength concrete materials, and the remaining cavity is used as cast-in-place concrete after assembly to enhance the overall structural earthquake resistance and disaster safety performance. At the same time, each wall module needs to be designed through effective spatial connection process design and digital simulation analysis to avoid spatial collision and conflicts before and after the assembly process. 3D printing materials, processes and industrial reinforcement technology are used to organically combine the seismic structure of the building structure, structural load-bearing requirements and construction and installation, and integrate intelligent construction.

[0028] like Figure 7 As shown, the upper part of each high-strength concrete wall is installed in place by hooks 3 using traditional lifting equipment, and the structural column reinforcement of the module is realized by using the stirrups 4 and longitudinal bars 5 extending from the top surface of the foundation. The reinforcement connection between the No. 1 wall 1 and the No. 2 wall 6 is realized by inserting the pin bar 2 into the 3D printed wall connection node with a cavity design. The wall inserts the longitudinal steel bar 7 into the cavity to strengthen the connection between the bottom wall module and the upper and lower blocks by strengthening the cast-in-place concrete. The No. 3 wall 8 and the No. 2 wall 6 are enclosed by the longitudinal bars and stirrups of the structural column through the printed single-side extended wall shell, and the rigid connection from the foundation to the bottom block is realized by assembling and installing the cast-in-place concrete.

[0029] The connection types of these three spatial special-shaped reinforced walls in this case cover all node design conditions in small buildings. The detailed structural design details are shown in Figure 8As shown, the materials and construction process of 3D printed concrete are fully utilized for reinforcement and connection. Wall No. 4 10 and Wall No. 2 6 surround the longitudinal reinforcement and stirrups of the structural column through a half-concave wall shell, and a rigid connection from the foundation to the bottom block is achieved through cast-in-place concrete. The connection segments of the special-shaped wall modules with cavity design can be divided into three types, 11 is I-type, 12 is T-type, and 13 is L-type, which respectively realize one-way connection, two-way connection and three-way connection. For large-scale building space areas and module divisions, more complex space segment structures will appear. These three types of connection segments can be referred to for spatial symmetrical arrangement, and digital spatial reinforcement prefabrication can be realized in the process of printing and making digital special-shaped wall space models, and spatial multi-directional rigid connection of multi-directional working conditions can be realized in assembly and post-cast-in-place processes.

[0030] This case only shows the application and implementation of the method of the present invention in a flat reinforced concrete dwelling, but the present invention is not limited to this structural type, building material and construction process. When the building form is spatially irregular and the building material is other materials, the method, steps and techniques of the present invention can also be used to carry out digital design and modular assembly construction of 3D printed irregular reinforced walls, with digitally designed circular ring beam reinforcement and arc-shaped structural column reinforcement embedded in the irregular wall, and modularly assembled and cast in situ to form an integral irregular frame structure to achieve fast, accurate and safe intelligent construction of any form of building structure.

[0031] The modular assembly intelligent construction method of 3D printed spatial special-shaped reinforced walls disclosed in this application is applicable to the intelligent construction of various spatial form building structures under various construction environments, and realizes the industrialized digital assembly construction of the civil engineering industry. The digital model of complex spatial buildings is established through artificial intelligence, and the building functions and structural construction processes are split into basic spatial special-shaped wall modules. The 3D printing integrated digital production module is used and spatial reinforcement is performed during the printing process to simplify multiple traditional construction processes. The integrated digital building design system is realized by combining the printing material design, functional material design and post-casting material design with the structural modular design, reinforcement design and assembly process design. The present invention realizes the rigid connection of various special-shaped wall modules to ensure the integrity and safety of the structure through the combination of special-shaped spatial wall cavity design, printing material design, post-assembly cast-in-place materials and printing cavity spatial reinforcement technology. The method has universal applicability to existing traditional building materials and new building materials, and has outstanding technical advantages of high precision, high efficiency, digitization and intelligence compared with existing construction technologies.

[0032] The specific implementation methods described above provide a detailed description of the technical solutions and beneficial effects of the present invention. It should be understood that the above is only the most preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, supplements and equivalent substitutions made within the scope of the principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls, characterized in that; 3D printing is used to manufacture special-shaped walls, which are assembled as modular units to form the main body of the building.

2. A modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls according to claim 1, characterized in that ； Get custom architectural renderings; Based on the classical phase theory, space recognition is performed to form the building space outline and structured light three-dimensional model; A modular assembly solution for forming special-shaped walls based on building information and assembly technology using 3D models; Based on the modular assembly solution, 3D printing technology is used to manufacture special-shaped walls, which are then assembled to form the main body of the building.

3. A modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls according to claim 2, characterized in that; The modular assembly scheme is obtained in the following way: the three-dimensional model is divided into blocks in layers along the height direction according to the scale, shape, and construction process, and the modules of the special-shaped wall are divided according to the layout, function, and size of each block, taking into account the lifting parameters and assembly process.

4. A modular assembly intelligent construction method for 3D printed spatial special-shaped reinforced walls according to claim 1 or 2, characterized in that ； Design the cavity of special-shaped walls, consider the load-bearing, function and structure by using computer numerical simulation and digital space information analysis, design the reinforcement and structural connection scheme for special-shaped walls, and reinforce the special-shaped walls during the 3D printing process; The special-shaped walls are assembled on site and the joints of the assembly are cast in situ.

5. A modular assembly intelligent construction method for 3D printed spatial special-shaped walls according to claim 1 or 2, characterized in that; The special-shaped wall is formed by a combination design of 3D printing materials, functional filling materials, assembled cast-in-place materials and space shapes.

6. A modular assembly intelligent construction method for 3D printed spatial special-shaped walls according to claim 1, characterized in that; Applicable to the intelligent construction of various spatial forms of building structures in various construction environments.

Images