METHOD FOR PRODUCING CONCRETE COMPONENTS WITH AT LEAST ONE CONTINUOUS CHANGE IN PROPERTIES

Description

[0001] The invention relates to a method for producing at least one concrete component which is provided with at least one continuous or approximately continuous change in properties in at least one spatial direction.

[0002] Concrete components made from homogeneous concrete mixes (ranging from ultra-high-performance concrete to ultra-lightweight concrete) are known in the prior art. Sandwich-like and multi-layered concrete components are also known, featuring layers with abrupt, stepwise changes in properties. Such concrete components are typically manufactured by casting, wet spraying, or dry spraying. Multifunctional components created using a material mix (e.g., external thermal insulation composite systems) are also known. Optimizing components by modifying their geometry (lightweight structural design) is another known approach. A disadvantage of these known components is that they are often insufficiently adapted to the actual load-bearing and building physics requirements, leading to high material consumption, increased weight, high transportation costs, resource waste, and high CO₂ emissions.

[0003] In light of the above, it will be apparent to those skilled in the art from this disclosure that there is a need to solve or overcome the problems or disadvantages described above. The invention addresses this need arising from the prior art, as well as other needs that will be apparent to those skilled in the art from this disclosure.

[0004] WO 2007 / 056353 A2 discloses a method for producing at least one concrete component, wherein Material for forming the component is dosed by means of at least one of at least two dosing devices, material for forming the component is dosed by means of at least one other of the at least two dosing devices, and material is dispensed by means of at least one dispensing device arranged downstream of the at least two dosing devices in order to produce the component, and wherein the at least one dispensing device is moved by means of an automated motion device.

[0005] The problems arising from the above can be solved in particular by the features of the independent claims. However, the invention is not limited to embodiments that eliminate all the aforementioned problems or disadvantages of the prior art. Rather, the invention also claims general protection for the embodiments described below.

[0006] The claim does not include a device for producing at least one component, in particular a concrete component, a mineral-bound component, preferably a component containing predominantly inorganic material and / or a component held together by means of a binder.

[0007] In particular, the device has at least two, preferably separate and / or parallel, dispensing devices, wherein at least one of the at least two dispensing devices is designed to dispense material for the component, and at least one other of the at least two dispensing devices is designed to dispense material for the component in a suitably variable manner, at least temporarily.

[0008] The device further comprises at least one dispensing device for dispensing (preferably the metered and / or variably metered) material.

[0009] The component is advantageously manufactured such that it is provided with at least one continuous (in particular graded) or approximately continuous (in particular graded) property change in at least one spatial direction, preferably two or three spatial directions. The property change is expediently a functional property change.

[0010] For the sake of brevity, the "at least a continuous or approximately continuous change in properties" will usually be referred to as "continuous change in properties" below.

[0011] Continuous property modification advantageously allows the component to be adapted to a (suitably occurring) building physics and / or structural requirements profile. Thus, the component composition / structure preferably follows a building physics and / or structural requirements profile. This allows, for example, an at least approximately homogeneous stress state, improved thermal insulation properties, and multifunctionality (e.g., load-bearing, insulating, sealing) of the component to be achieved. For example, continuous property modification can improve the component properties by locally adapting the porosity, and thus the strength and stiffness, to actual stress conditions occurring within the component, e.g., by means of lightweight aggregates, pore-forming agents, etc. Consequently, mass and material savings are possible, and, for example,Smaller component dimensions are achievable, resulting in a more positive environmental footprint compared to conventional components. In building construction, the savings in mass and materials also advantageously lead to a gain in usable floor space.

[0012] Furthermore, the continuous change in properties ensures a permanent bond between component areas of different material compositions, especially concrete compositions.

[0013] Continuous property modification can serve not only to adapt the component to structural and building physics requirements, but also to adapt it to economic and ecological requirements. For example, resource efficiency, CO2 footprint, reduction of embodied energy in the component, and / or improved recyclability, etc., can be achieved.

[0014] The continuous change in properties particularly affects at least one of the following: thermal conductivity, strength, stiffness, bulk density, porosity, air void content, pigmentation, water content, fiber content, water vapor diffusion resistance, water penetration depth and content and type of aggregates, additives, admixtures and other possible component components, especially concrete component components.

[0015] This enables, in particular, the production of single-material components, e.g., purely mineral, yet multifunctional components. Thus, the need for a disadvantageous mix of impure materials (poor recyclability) can be avoided, while still achieving advantageously reduced component dimensions.

[0016] This component is particularly useful in building construction and / or civil engineering and can be designed, for example, as part of the building envelope, exterior wall, cladding panel, as part of the load-bearing structure, floor slab, beam, wall, girder, girder, column, retaining wall, foundation, noise barrier, exterior design, partition wall, tunnel wall, bridge structure, roadway slab, tank, pipe, etc.

[0017] Continuous property change includes, in particular, a smooth, graded, continuous, and / or stepless property change. Approximate continuous property change includes, in particular, a stepwise or discontinuous property change, which can be achieved, for example, by means of a multi-layer structure or another suitable approximation structure. The approximate continuous property change, especially the multi-layer structure, is preferably approximated to continuous property change in such a way that the deviation from continuous property change is expediently negligible with regard to the required structural and / or building physics performance profile.For example, the approximate continuous property change can be approximated by a multilayer structure that has at least 5, 10, 15, 20, 25, 50, 75 or 100 different layers.

[0018] The change in properties can occur inside the component and / or on the surface of the component.

[0019] The at least one dispensing device is preferably located downstream of the at least two metering devices. Preferably, the material supplied to one metering device differs from the material supplied to the other metering device, e.g., in type, composition, and / or properties. It is particularly preferred that the material supplied to one metering device has reciprocal or opposite properties relative to the material supplied to the other metering device, e.g., one with high density, strength, and thermal conductivity, and the other with low density, strength, and thermal conductivity.

[0020] Within the scope of the invention, the term "material" includes, in particular, materials and / or mixtures of materials, e.g., liquid material, granulated material, water, cement, aggregates, additives, admixtures, air pores, functional materials, gypsum, plaster, fibers, displacement bodies, plastic foam bodies, hollow bodies, or other, e.g., prefabricated functional bodies (of any size, geometry, and / or density, e.g., with diameters of several centimeters, approximately larger than 5, 10, 15, or 20 cm, preferably made of ultra-high-performance fiber-reinforced fine-grained concrete), etc., and / or a mixture thereof. The material can, in particular, be provided in quasi-pure form and / or in mixture form.

[0021] It is possible that at least two dosing devices are designed to variably dose material for forming the component.

[0022] The device preferably comprises a measure that ensures that a material dispensed by one of the at least two dispensing devices and a material variably dispensed by another of the at least two dispensing devices are mixed together. The at least one measure is preferably located downstream of the at least two dispensing devices. It is possible that the continuous change in properties is achieved by varying the dispensing rate and / or by varying the mixing ratio of the materials. The variable dispensing and / or the variation preferably occurs continuously (e.g., in a graduated manner), particularly in a flowing manner.

[0023] For example, mixing can be done from virtually pure starting materials or from premixed material mixtures, or a premixed material mixture or a virtually pure starting material can be modified by adding further materials / material mixtures.

[0024] The device may include at least one mixing device (e.g., a continuous mixer, a mixer that mixes through the geometry of its mixing chamber, a static mixer, a dynamic mixer, a mixing device that mixes by means of compressed air turbulence (e.g., using a ring nozzle), etc.). Preferably, the mixing device is configured to mix a material metered by one of the at least two metering devices with a material that has been variably metered by another of the at least two metering devices. For example, the mixing device may be arranged upstream of the at least one dispensing device or within the at least one dispensing device.

[0025] The device may have at least two, three, or more than three dispensing devices, preferably arranged in parallel, for dispensing material. The at least two dispensing devices are preferably arranged downstream of the at least two metering devices.

[0026] Preferably, at least one first dispensing device is configured to dispense material metered by one of the at least two metering devices by means of a spray jet, and a second dispensing device is configured to dispense material variably metered by another of the at least two metering devices by means of a spray jet. In particular, the at least one first and second dispensing device are configured such that the material dispensed from the first dispensing device and the material dispensed from the second dispensing device mix with each other through overlapping spray jets. In this embodiment, the mixing takes place in the spray mist and / or downstream outside the at least one first and second dispensing device, or preferably generally outside the device. The spray jets are preferably spray cones.

[0027] Metered material can therefore be mixed with variably metered material, or vice versa, particularly upstream, in, and / or downstream of at least one dispensing device. This mixing is carried out continuously (e.g., graduated, continuous).

[0028] It is possible that at least one of the at least two dosing devices (preferably both dosing devices) is designed to continuously or approximately continuously dispense variable amounts of material. For example, the variable dosage can be changed over a period of at least 1, 5, 10, 15, 30, 60, 120, or 180 seconds. It is also possible that the at least two dosing devices can, at least temporarily, dispense in a conventional manner.

[0029] Continuously variable dosing includes, in particular, flowing, graded, steady, and / or stepless dosing. An approximately continuously variable dosing system includes, in particular, stepwise or discontinuous dosing. The approximately continuously variable dosing system is approximated to continuously variable dosing, in particular, by means of at least 5, 10, 15, 20, 25, 50, 75, or 100 approximation steps, whereby the approximately continuous property change generated in the component is advantageously negligible compared to the continuous property change with regard to a desired structural and / or building physics requirement profile.

[0030] Preferably, the at least one dispensing device is a spraying device for dispensing material, particularly to achieve a uniform application of the material. The spraying can be carried out, for example, using a wet or dry spraying process. Preferably, the at least one dispensing device includes a compressed air connection for dispensing the material with compressed air assistance.

[0031] It is also possible that at least one dispensing device is a feed bar for pouring material, e.g., layer by layer, particularly to achieve a linear material application. The feed bar can, for example, have slot-shaped openings (e.g., opposite and / or offset from each other), especially for material intake on one side and material output of a defined width on the other. In this case, the material is preferably dispensed without compressed air.

[0032] It is also possible that at least one output device is a printhead or a nozzle for dispensing material droplets and / or continuously, in particular to achieve a point-by-point, discrete, and / or line-like material application. Preferably, the material is dispensed continuously and / or without compressed air.

[0033] Preferably, the device comprises a motion device (guide device), which is particularly automated, for moving (guiding) the at least one output device. The motion device can, for example, pivot, rotate, move horizontally, move vertically, move in an arc, etc., the at least one output device. The motion device serves in particular for the precise positioning and / or alignment of the at least one output device.

[0034] The motion device may include a distribution mast or articulated arm (e.g., a multi-jointed distribution mast or multi-jointed arm). It may also include a robot, in particular a 5-axis or 6-axis robot. The motion device may also include a gantry structure, which is preferably movable and / or on which at least one dispensing device is movably arranged, preferably horizontally, axially, and / or pivotably.

[0035] It is possible that the motion device comprises a preferably uniaxially and / or vertically movable holding structure that supports a plurality of output devices, e.g., arranged in a grid pattern (e.g., at least three, four, eight, or twelve). Advantageously, the output devices can be controlled individually differently (e.g., for multi-axis property changes) or collectively in the same way (e.g., for uni-axis property changes).

[0036] Preferably, the at least two dosing units in the plant are controlled individually. Likewise, several dispensing units in the plant can be controlled individually.

[0037] It is possible that the device includes at least one detection device for detecting at least one component-specific, component-influencing, and / or device-specific state parameter (e.g., state variable, state property, positioning, etc.). Detection can occur, for example, before, during, and / or after the manufacturing of the component.

[0038] The recording device is preferably movable together with the at least one output device and is attached, for example, to the at least one output device or to the movement device.

[0039] It is also possible that the detection device is stationary, meaning it is not moved with the output or movement device. The stationary detection device is, for example, positioned outside of the formwork for the component or integrated into the formwork for the component.

[0040] It is possible that the device includes a detection unit for recording at least one material flow-specific state parameter, which is present, for example, within the device (e.g., volume flow, state variable, state property, etc.). This recording can take place, for example, before, during, and / or after the manufacturing of the component.

[0041] The component-specific condition parameter includes, in particular, at least one of the following: geometry, layer thickness, position, dimensions, composition, microstructure, and presence of the material application and thus of the component or at least a part thereof, and any other properties characterizing the component or the material application. The component-influencing condition parameter includes, in particular, at least one of the following: geometry, position, location, orientation, and presence of reinforcement for the component, an embedded component for the component, or generally other condition parameters found at the manufacturing site of the component that influence the component and / or the manufacturing process; material in flight, dispensed by means of at least one dispensing device (e.g., spray jet(s), etc.); the distance of the at least one dispensing device to the material application, the formwork, the embedded component, etc.; and further, for example...Climatic state parameters such as air temperature, humidity, etc. The device-specific state parameter includes, in particular, at least one of the following: position, orientation, and speed of the at least one output device and / or the motion device, and, more generally, parameters characterizing the device (e.g., static and / or dynamic properties). The material flow-specific state parameter includes at least one of the following: one or more material volume flows, composition and consistency of the material volume flows, conveying pressure, etc. The aforementioned state parameters can be, for example, changing, dynamic, static, unchanging, etc. states, characteristics, properties, etc.

[0042] Data acquisition includes, in particular, measuring, surveying, detecting, and / or monitoring. The at least one acquisition device can therefore be a measuring device, surveying device, detection device, and / or monitoring device (e.g., sensor, laser sensor, laser point sensor, 3D laser scanner, pressure sensor, etc.), which, for example, makes it possible to determine whether the component is being manufactured correctly.

[0043] Preferably, the device comprises a control device, in particular an electronic one (e.g., a control and / or regulating device), which is preferably connected to at least one control section (e.g., a controllable and / or regulating section) in order to control (e.g., to regulate and / or control) the at least one control section and / or the dispensing of at least one of the at least two dispensing devices, e.g., by means of at least one actuator, valve, or other suitable means, preferably in real time. In a particularly emphasized embodiment of the invention, a control device is connected to one of the at least two dispensing devices to control the dispensing, and / or to the other of the at least two dispensing devices to control the dispensing in such a way that it is variable, e.g.,as mentioned above, depending on at least one state parameter described above and / or a computer-generated model of the component to be manufactured described below.

[0044] The control device is preferably connected to at least one of the two detection devices and / or the at least one control section by means of a control circuit (control and / or regulation circuit).

[0045] The control device is preferably designed to control the at least one control section depending on the at least one state parameter detected by the first and / or second detection device, e.g. via the control circuit.

[0046] The control device is furthermore specifically designed to control at least one control section based on a computer-generated model (3D CAD design - CAD: Computer Aided Design) of the component to be manufactured, in particular the data / information representing this model. For this purpose, the control device may, for example, include a storage unit in which the computer-generated model, in particular this data / information, can be stored, and / or an interface for transferring the computer-generated model, in particular this data / information, to the control device. The computer-generated model may include the component geometry to be achieved, the material structure to be achieved, and / or the material composition of the component to be achieved (e.g.,Type, porosity, air void content, pigmentation, distribution of materials, composition of materials, fiber and reinforcement content, mechanical properties, etc.).

[0047] Active control (regulation, control) or influencing of at least one control section is therefore possible based on a comparison of the actual and target states, in particular by recording at least one state parameter (actual value), comparing it with the target value (e.g. from a computer-generated model), correspondingly controlling or influencing the control section, and if necessary, re-recording, comparing, correspondingly controlling, etc.

[0048] It should be noted that the device has at least one, preferably two, conveying devices (e.g., pumps, screw pumps, etc.) for conveying the materials, which are preferably arranged upstream of the at least two metering devices. At least one of the at least two metering devices can be designed as a conveying device.

[0049] The at least one control section can be, for example, one of the following: one of the at least two dosing devices in order to advantageously control the dosing, the other of the at least two dosing devices in order to advantageously control the variable dosing, the at least one dispensing device, a plurality of dispensing devices which, for example, can be controlled individually differently or collectively in the same way, the at least one measure, the movement device and / or the at least two conveying devices for conveying the materials and other suitable variable device parameters.

[0050] It should be mentioned that at least one of the two dosing devices can be designed as a flow restrictor, valve, etc.

[0051] The device may comprise at least three, four, eight, or twelve output devices, arranged, for example, in a grid or in a row adjacent to one another. As mentioned above, the output devices may be controlled individually differently (e.g., for multi-axis property changes) or collectively in the same way (e.g., for single-axis property changes).

[0052] The at least two dosing devices are arranged in parallel and / or designed for independent dosing. Furthermore, the at least two dispensing devices are also arranged in parallel, which is expediently also true for the at least two conveying devices.

[0053] Furthermore, it should be mentioned that the individual devices described above, such as the dosing devices, the mixing device and / or the dispensing device, can be combined into devices that fulfill several of the aforementioned functions simultaneously.

[0054] It is possible that the dosing to be carried out by means of at least one dosing device and the variable dosing to be carried out by means of at least one other dosing device are carried out simultaneously, overlapping in time and / or at intervals in time, e.g. one after the other.

[0055] The invention comprises a method for producing at least one concrete component according to the subject matter of claim 1. The method is preferably carried out with a device as described herein.

[0056] According to the invention, in the method, material for forming the component is metered by means of at least one of at least two metering devices.

[0057] Furthermore, material for forming the component is variably dosed by means of at least one other of the at least two dosing devices.

[0058] Furthermore, material is dispensed by means of at least one dispensing device arranged downstream of the at least two dispensing devices in order to produce the component and to provide it with at least one continuous or approximately continuous change in properties in at least one spatial direction, preferably two or three spatial directions.

[0059] It is possible that the component produced using the method according to the invention may be further processed and / or modified.

[0060] The method of the invention may further comprise one or more of the following features: It is possible that material dispensed by one of the at least two dispensing devices and material variably dispensed by the other of the at least two dispensing devices are mixed together, and preferably a mixing ratio is formed, wherein the change in properties is achieved by varying the mixing ratio.

[0061] Furthermore, material that has been dosed by one of the at least two dosing devices and material that has been variably dosed by the other of the at least two dosing devices can be mixed together by means of at least one mixing device that is arranged upstream of the at least one dispensing device or in the at least one dispensing device.

[0062] At least one first dispensing device can dispense material dispensed by one of the at least two metering devices by means of a spray jet, and a second dispensing device can dispense material variably dispensed by the other of the at least two metering devices by means of a spray jet. The material dispensed from the first dispensing device and the material dispensed from the second dispensing device can mix with each other through overlapping spray jets. Preferably, at least one of the at least two metering devices dispenses material continuously or approximately continuously.

[0063] The at least one output device can be, for example, a spray device that dispenses material, particularly to achieve a surface-wide material application. The at least one output device can be a feed bar that pours material, particularly to achieve a linear material application. However, the at least one output device can also be a print head or a nozzle that dispenses material droplets or continuously, particularly to achieve a point-by-point or discrete material application.

[0064] According to the invention, at least one output device is moved by means of an automated motion device.

[0065] It is possible that at least one component-specific, component-influencing and / or device-specific state parameter is detected by means of at least one first detection device, wherein preferably the at least one detection device is moved together with the at least one output device or is stationary.

[0066] It is also possible that at least one material flow-specific state parameter present within the device for manufacturing the component is detected by means of at least one second detection device.

[0067] A control device can expediently control at least one control section or the dosing of at least one of the at least two dosing devices, preferably in real time.

[0068] The control device can preferably control at least one control section depending on the at least one state parameter detected by the first and / or second detection device.

[0069] The control device can expediently control at least one control section depending on a computer-generated model of the component to be manufactured.

[0070] The at least one control section preferably comprises at least one of the following: one of the at least two dosing devices, the other of the at least two dosing devices, in particular to control the variable dosing, the at least one dispensing device, a plurality of dispensing devices that can be controlled individually differently or collectively in the same way, the at least one mixing device, the movement device, and / or at least one of at least two conveying devices for conveying the materials.

[0071] Other advantageous embodiments of the invention are disclosed in the dependent claims or will become apparent from the following description of the preferred embodiments of the invention in conjunction with the accompanying figures. Figure 1: schematically shows a principle representation of a device for manufacturing a component; Figure 2: schematically shows a mixing principle according to one embodiment of the invention; Figure 3: schematically shows a mixing principle according to another embodiment of the invention; Figure 4: schematically shows a mixing principle according to yet another embodiment of the invention; Figure 5: shows an embodiment according to the invention in which a mixing process of the materials for forming the component takes place upstream of an output device; Figure 6: shows an embodiment according to the invention in which a mixing process of the materials for forming the component takes place within an output device; Figure 7: shows an embodiment according to the invention in which a mixing process of the materials for forming the component takes place downstream outside of two output devices or generally outside the device for manufacturing the component.Figure 8: schematically shows a material application principle according to an embodiment of the invention, in which the materials for forming the component are dispensed by means of a printhead; Figure 9: schematically shows a material application principle according to an embodiment of the invention, in which the materials for forming the component are dispensed by means of an application bar; Figure 10: schematically shows a material application principle according to an embodiment of the invention, in which the materials for forming the component are sprayed off by means of a spraying device; Figure 11: shows a movement device in the form of a distribution mast or articulated arm according to an embodiment of the invention; Figure 12: shows a movement device in the form of a movable portal structure on which a dispensing device is movably mounted, according to an embodiment of the invention.Figure 13: shows a motion device with a plurality of output devices arranged in a grid according to one embodiment of the invention; Figure 14: shows a schematic representation of states found before and during the manufacture of the component, as well as possible types and positions of detection devices; Figure 15: shows a schematic principle diagram according to one embodiment of the invention, in which the materials for forming the component are mixed together downstream outside of two output devices in a spray mist; Figure 16: shows a schematic principle diagram according to another embodiment of the invention, in which the materials for forming the component are mixed together downstream outside of three output devices in a spray mist; Figure 17: shows a component with one-dimensional continuous or approximately continuous property change.Figure 18 shows a component with a two-dimensional continuous or approximately continuous property change; Figure 19 shows a component with a three-dimensional continuous or approximately continuous property change; Figure 20 shows a schematic representation of the generation and resulting microstructure of a continuous or approximately continuous property change according to one embodiment of the invention; Figure 21 shows a flowchart of a method according to one embodiment of the invention; and Figure 22 shows a flowchart of a method according to another embodiment of the invention.

[0072] The embodiments shown in the figures are partly identical, with similar or identical parts being provided with the same reference numerals, and reference is also made to the description of one or more other embodiments to avoid repetition.

[0073] Figure 1 Figure 1 schematically shows a principle representation of an unclaimed device 1 for manufacturing a component. The component to be manufactured is a concrete component, a mineral-bonded component, a component containing inorganic material, or a component held together by a binder. The device 1 has three separate, parallel metering units 10, which can be supplied with different materials for forming the component via three parallel feeds 20. The materials can be supplied to the three metering units 10, for example, in quasi-pure form or as mixtures. The three metering units 10 are designed to continuously, and in particular to modulate, the supplied material.

[0074] The device 1 comprises a measure 40.1, which ensures that the metered materials are mixed together. The measure 40.1 is formed by a mixing device arranged downstream of the three metering devices 10. The device 1 also comprises three parallel conveying devices 80 for conveying the materials. The device 1 further comprises a dispensing device 30 arranged downstream of the three metering devices and downstream of measure 40.1 for dispensing the metered and mixed materials by means of a spray jet ST in order to create a material application MA in a mold 100 and to produce the component. The component is produced such that it is provided with at least one functional continuous property change in at least one spatial direction.

[0075] The device 1 also includes a motion device 50 for moving the output device 30 during the manufacture of the component and a detection device 60, which, with reference to the Figures 11 to 14 will be described in more detail.

[0076] Furthermore, the device 1 includes a control section (in Figure 1(schematically indicated by the arrow) and a control device (control / regulating device) 70, which is connected to the control section and the detection device 60. The control device 70 is designed to control the control section, e.g., by means of one or more actuators, depending on the state parameters detected by the detection device 60 and depending on a 3D CAD model (CAD: Computer Added Design) of the component to be manufactured. The control section comprises the motion device 50 and the three dosing devices 10, which makes it possible, in particular, to control continuous dosing. It is also possible that the control section includes further devices of the apparatus 1, e.g., the mixing device 40.1, the dispensing device 30, and the conveying devices 80.Alternatively or additionally, the control can be carried out depending on material flow-specific state parameters that are present during the manufacturing process within the device 1 and are detected by means of a further detection device connected to the control device 70, which is not shown.

[0077] Figure 2 Figure 1 schematically shows a mixing principle according to one embodiment of the invention. The mixing principle is based on two, for example, homogeneous starting mixtures A and B, which preferably have reciprocal properties (e.g., starting mixture A with high density, high strength and high thermal conductivity and starting mixture B with low density, low strength and low thermal conductivity). Figure 3Figure 1 schematically shows a mixing principle according to another embodiment of the invention. The mixing principle is based on a starting mixture which is modified by adding further materials such as aggregates (e.g. gravel, sand, crushed stone or other common concrete aggregates) and / or additives (e.g. color pigments, organic substances, fibers and other common concrete additives). Figure 4 Figure 1 schematically illustrates a mixing principle according to yet another embodiment of the invention. The mixing principle is based on the fact that the materials for forming the component, such as water, cement, aggregates, additives, and admixtures, are mixed together virtually in their pure form. With reference to the Figures 2 to 4 The continuous change in properties is achieved by varying the mixing ratio of the starting materials and, in particular, by appropriately varying the dosage of the starting materials.

[0078] Figure 5Figure 40.1 shows a measure according to an embodiment of the invention, which ensures that the different materials for forming the component are mixed together. Measure 40.1 comprises a mixing device arranged upstream of the output device 30. The mixing device can, for example, be a continuous mixer.

[0079] Figure 6 Figure 40.2 shows a measure according to another embodiment of the invention, which ensures that the different materials are mixed together to form the component. Measure 40.2 comprises a mixing device housed in the dispensing device 30. The mixing device can, for example, be a mixing device that generates a mixture through the geometry of its mixing chamber, or a mixing device that generates a mixture by means of compressed air turbulence (e.g., with the aid of a ring nozzle).

[0080] Figure 7Figure 40.3 shows a measure according to yet another embodiment of the invention, which ensures that the different materials for forming the component are mixed together. Measure 40.3 comprises two dispensing devices 30, which are configured such that the materials are dispensed by means of spray jets and mixed together by the overlapping of the spray jets, which consequently takes place downstream outside the two dispensing devices 30. The mixing process can be carried out, for example, by means of a wet or dry spraying process, in which, preferably, two homogeneous initial mixtures are conveyed in parallel and metered separately beforehand.

[0081] Figure 8 schematically shows a material application MA according to one embodiment of the invention. The in Figure 8The dispensing device 30 shown is designed as a printhead or nozzle to dispense the materials drop by drop and / or continuously, thereby achieving a spot or discrete material application. The material application takes place without compressed air.

[0082] Figure 9 Figure 30 schematically shows a material application MA according to another embodiment of the invention. The dispensing device 30 is designed as a feed bar to preferably pour the materials for forming the component layer by layer, thereby achieving a linear material application MA. The feed bar comprises slot-shaped openings arranged opposite or offset from one another for receiving material on one side and dispensing material of a defined width on the other side. The width of the feed bar is less than or equal to the width of the formwork 100. The material application is carried out without compressed air.

[0083] Figure 10Figure 3 schematically shows a material application MA according to yet another embodiment of the invention. The dispensing device 30 is designed as a spraying device to spray the materials for forming the component, thereby achieving a surface-wide material application. The spraying can be carried out using a wet or dry spraying process. The material application is carried out using compressed air.

[0084] Figure 11Figure 1 schematically shows a principle representation of an automated motion device 50 for moving the dispensing device 30 according to an embodiment of the invention. The motion device 50 is a distribution mast or articulated arm with multiple degrees of freedom. The motion device 50 can, for example, be a 5-axis or 6-axis robot. The spray axis of the dispensing device 30 can thus always be aligned orthogonally to the tangential plane at the application point. Possible locations for use include, for example, in situ, prefabrication plants, or field factories. This embodiment advantageously enables, for example, the use of curved components. Figure 11 The arrows shown symbolize, by way of example, the movement possibilities of the movement device 50.

[0085] Figure 12Figure 1 schematically shows a principle representation of an automated motion device 50 for moving the output device 30 according to an embodiment of the invention. The motion device 50 comprises a portal structure on which an output device 30 is movably mounted, e.g., horizontally and vertically movable and, if necessary, pivotable. The portal structure is horizontally movable. The in Figure 12 The arrows shown symbolize the movement possibilities of the movement device 50 and the output device 30.

[0086] Figure 13Figure 1 shows an automated motion device 50 for moving a plurality of output devices 30 according to yet another embodiment of the invention. The motion device 50 comprises a movable holding structure that holds a plurality of output devices 30 arranged in a grid. The holding structure, and thus the grid of the plurality of output devices 30, is preferably uniaxially and, in particular, vertically movable. This advantageously enables the economical production of planar components, e.g., in precast concrete plants. Furthermore, stepless property transitions in the Z-axis are advantageously enabled.

[0087] Figure 14Figure 1 shows a schematic representation of conditions that can be found at the manufacturing site before and during the production of the component, and several detection devices 60, 60', 60'' for capturing corresponding condition parameters. Detection devices 60 and 60' are used to measure and detect component-specific (e.g., composition, geometry, layer thickness, material density, component properties, etc.), component-influencing (e.g., formwork 100, reinforcement 101, embedded part 102, temperature, humidity, etc.), and device-specific (e.g., position, speed, orientation, etc. of output device 30 or movement device 50) condition parameters. Detection device 60 is movable together with output device 30 and is designed as a laser point sensor. Detection device 60' is stationary, independent of output device 30, and is designed as a 3D laser scanner.The 60" detection unit is integrated into the 100 formwork and can, for example, detect the weight of the material application or the presence of material application. The 60" detection unit is designed as a pressure sensor.

[0088] The sensing devices 60, 60' and 60'' and their output data are integrated into and considered in the process chain for manufacturing the component. In particular, if material flow-specific state parameters (e.g., one or more parallel material volume flows, consistency and / or composition of the material volume flows, conveying pressure, etc.) are simultaneously acquired within the device 1 by means of another sensing device (not shown) and feedback with a control circuit, the control section (i.e., in particular the variable device parameters), which thus represents a control section, can be controlled in real time.

[0089] Figure 15Figure 1 schematically shows a principle diagram according to an embodiment of the invention. The embodiment comprises two parallel material containers X and Y, two parallel conveying devices 80, two parallel metering devices 10, and two parallel dispensing devices 30. The two dispensing devices 30 each include a compressed air connection 31 for compressed air-assisted dispensing.

[0090] Material container X is intended for a starting mixture A. The starting mixture A is conveyed by the conveying device 80 to the metering device 10, metered by the metering device 10, and forwarded to the dispensing device 30, which dispenses the starting mixture A by means of a spray jet ST1. Material container Y is intended for a starting mixture B. The starting mixture B is conveyed by the other conveying device 80 to the other metering device 10, metered continuously and variably by means of the other metering device 10, and forwarded to the other dispensing device 30, which dispenses the starting mixture B by means of a spray jet ST2. The dispensing devices 30 are designed such that the spray jets ST1 and ST2 overlap, thus mixing the starting materials A and B together.

[0091] Figure 16Figure 1 shows yet another embodiment of the invention, in which three dispensing devices 30 are configured to dispense material by means of a spray jet ST1, ST2, ST3, respectively. Additives are supplied to one of the dispensing devices 30, a starting mixture is supplied to another dispensing device 30, and additives are supplied to the remaining dispensing device 30. The dispensing devices 30 are configured such that the additive spray jet ST1, the starting mixture spray jet ST3, and the additive spray jet ST2 overlap in such a way that the additives, the starting mixture, and the additives are mixed together.

[0092] Figure 17This schematically depicts a component BT with a continuous (graded) or approximately continuous (graded) change in properties in one spatial direction. The varying circle diameters symbolize the change in the material composition and thus in the properties of component BT. Application examples include planar components, walls, cladding panels, etc.

[0093] Figure 18 The figure schematically shows a representation of a component BT with continuous (graded) or approximately continuous (graded) property changes in two spatial directions. Here, too, the varying circle diameters symbolize the change in the material composition and thus in the properties of component BT. Application examples include cylindrical components, columns, pipes, etc.

[0094] Figure 19The figure schematically shows a representation of a component BT with continuous (graded) or approximately continuous (graded) property changes in three spatial directions. Here, too, the varying circle diameters symbolize the change in the material composition and thus in the properties of component BT. Application examples include floor slabs, beams, cantilevers, etc.

[0095] The Figure 20 The figure schematically shows the generation and structure or microstructure of continuous (graded) or approximately continuous (graded) property changes through variation of the material composition and, in particular, the mixing ratio of the materials dosed by means of at least two dosing devices. Variable parameters include, for example, the content, size, packing density, type, orientation, and ratio of the different materials.

[0096] Figure 21shows a flowchart of a method for manufacturing a component, which is carried out with the device 1, according to an embodiment of the invention.

[0097] In step S1, material A (either in pure form or as a mixture) is fed to a dosing device 30. In a parallel step S1', a different material B (either in pure form or as a mixture) is fed to another dosing device 30.

[0098] In step S2, material A is dosed in a controlled manner (e.g., controlled or regulated) using a control device. In a parallel step S2', material B is dosed in a variable manner (e.g., controlled or regulated) using the same control device.

[0099] In step S3, material A is conveyed to output device 30. In a parallel step S3', material B is conveyed to another output device 30.

[0100] In step S4, material A is dispensed from one dispensing device 30 by means of a spray jet, and material B is dispensed from the other dispensing device 30 by means of a spray jet. The two spray jets overlap in such a way that materials A and B are mixed together. The mixing thus takes place downstream of the dispensing devices 30 in the spray mist. By appropriately dosing materials A and B, appropriately varying the mixing ratio of materials A and B, and appropriately moving the dispensing devices 30 by means of the movement device 50, a component with continuous or approximately continuous property changes can be produced.

[0101] Figure 22 shows a flowchart of a method for manufacturing a component, which is carried out with the device 1, according to another embodiment of the invention.

[0102] In step S1, material A (either in pure form or as a mixture) is fed to a dosing unit 30. In a parallel step S1', material B (either in pure form or as a mixture) is fed to another dosing unit 30.

[0103] In step S2, material A is dosed in a controlled manner (e.g., controlled or regulated) using a control device. In a parallel step S2', material B is dosed in a variable manner (e.g., controlled or regulated) using a control device.

[0104] In step S3, material A is conveyed to an output device 30. In a parallel step S3', material B is conveyed to the same output device 30.

[0105] In step S4, materials A and B are mixed together within the output device 30 by means of a mixing device. In an alternative embodiment, it is possible for materials A and B to be mixed together upstream outside the output device 30 by means of a mixing device.

[0106] In step S5, the mixed materials A and B are dispensed from the output device 30 to produce a component. The component is produced such that it has a graded property change in at least one spatial direction, preferably two or three spatial directions.

[0107] The in the Figure 21 and 22 Steps performed in parallel can also be carried out overlapping in time and / or sequentially.

[0108] The invention is not limited to the preferred embodiments described above. Rather, a multitude of variants and modifications are possible, which also make use of the inventive concept and therefore fall within the scope of protection defined by the appended claims.

Claims

1. Method for producing at least one concrete component, wherein - material for forming the component is metered by means of at least one of at least two metering devices (10), - material for forming the component is metered in a changeable manner by means of at least one other of the at least two metering devices (10), and - material is dispensed by at least one dispensing device (30) arranged downstream of the at least two metering devices (10) in order to produce the component and provide it with at least one continuous or approximately continuous property change in at least one spatial direction, and wherein - the at least one dispensing device (30) is moved by means of an automated movement device (50).

2. Method according to claim 1, wherein material, which has been metered by the one of the at least two metering devices (10), and material, which has been metered in a changeable manner by the other of the at least two metering devices (10), are mixed with one another and preferably a mixing ratio is formed, wherein, by variation of the mixing ratio, the property change is achieved.

3. Method according to claim 1 or 2, wherein material, which has been metered by the one of the at least two metering devices (10), and material, which has been metered in a changeable manner by the other of the at least two metering devices (10), are mixed with one another by at least one mixing device (40.1; 40.2) that is arranged upstream of the at least one dispensing device (30) or inside the at least one dispensing device (30).

4. Method according to any of the preceding claims, wherein at least one first dispensing device (30) dispenses material, which has been metered by the one of the at least two metering devices (10), by means of a spray jet (ST1), and a second dispensing device (30) dispenses material, which has been metered in a changeable manner by the other of the at least two metering devices (10), by means of a spray jet (ST2), and the material dispensed from the first dispensing device (30) and the material dispensed from the second dispensing device (30) are mixed with one another by intersecting of the spray jets (ST1, ST2).

5. Method according to any one of the preceding claims, wherein at least one of the at least two metering devices (10) meters material continuously or approximately continuously.

6. Method according to any one of the preceding claims, wherein the at least one dispensing device (30) is a spray device which sprays material, in particular in order to achieve a flat material application.

7. Method according to any one of the claims 1 to 5, wherein - the at least one dispensing device (30) is an inserter strip which casts material, in particular in order to achieve a linear material application, or - the at least one dispensing device (30) is a print head or a nozzle which dispenses material dropwise or continuously, in particular in order to achieve a pointwise or discrete material application.

8. Method according to any one of the preceding claims, wherein at least one condition parameter, specific to the component, influencing the component and / or specific to the device, is detected by at least one first detection device (60), wherein preferably the first detection device (60) is moved together with the at least one dispensing device (30), or is stationary.

9. Method according to any one of the preceding claims, wherein at least one material flow-specific condition parameter, which is present inside the device for producing the component, is detected by at least one second detection device.

10. Method according to any one of the preceding claims, wherein a control device (70) controls at least one control portion or the metering of at least one of the at least two metering devices (10), preferably in real time.

11. Method according to claim 10, wherein the control device (70) controls the at least one control portion in dependence of the at least one condition parameter detected by the first and / or second detection device (60).

12. Method according to anyone of claims 10 or 11, wherein the control device (70) controls the at least one control portion in dependence of a computer-generated model of the component which is to be produced.

13. Method according to anyone of claims 10 to 12, wherein the at least one control portion comprises at least one of the following: - the one of the at least two metering devices (10, - the other of the at least two metering devices (10), in particular in order to control the changeable metering, - the at least one dispensing device (30), - a plurality of dispensing devices (30), which can be controlled individually differently or collectively in the same manner, - the at least one mixing device, - the movement device (50), - at least one of at least two conveying devices (80) for conveying the materials.

14. Method according to any one of the preceding claims, wherein at least one of the at least two metering devices (10) meters material continuously or approximately continuously in a changeable manner.

15. Method according to any one of the preceding claims, wherein the movement device (50) - comprises a distributor mast or jointed arm, - comprises a robot, in particular a 5-axis or 6-axis robot, - comprises a portal structure, which is preferably movable and at which preferably at least one dispensing device (30) is movably arranged, and / or - comprises a holding structure which holds a plurality of dispensing devices (30) arranged in the form of a grid.