Curved panel manufacturing method and deformable formwork

Abstract

This technology makes it possible to manufacture panels with complex curved shapes, such as double curved shapes, using reusable molds, thereby reducing the workload and reducing waste material generation. [Solution] A flexible sheet is prepared, through which multiple wires are inserted so that they can move freely vertically, horizontally, and lengthwise, and which has an area wider than the projected area of ​​the desired curved panel when unfolded, and multiple pairs of vertically expandable supports that support both ends of the wires pulled out from the periphery of the flexible sheet and hold each wire in a spanning state.The process involves a formwork formation process in which the inside of the flexible sheet is held in a predetermined curved shape to form one side of the curved panel while adjusting at least one of the upper end position of the supports, the length and tension of the wires between the supports, and a mortar deposition process in which mortar is deposited on the flexible sheet held in the predetermined curved shape, and then the curved panel is manufactured by solidifying the mortar.

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a curved panel and a deformable formwork. [Background technology]

[0002] In recent years, the spread of 3D modeling software and visual programming among designers has led to an increase in demand for double-curved panels.However, in buildings constructed by combining multiple double-curved panels of different shapes, the enormous cost of producing the double-curved formwork, each of which has a different shape, is a problem, as is the large amount of waste generated by these formwork.

[0003] One proposed method for realizing a double-curved formwork with different shapes for each panel is to apply the cable-net formwork method. For example, Non-Patent Documents 1 and 2 disclose a method of forming a formwork by supporting a flexible sheet on a frame with wires, but in many cases the specifications are such that it cannot be reused, and it is not possible to produce a large number of panels with different shapes using a single formwork.

[0004] Multi-point mold construction methods are also attracting attention and are being used for actual building components. For example, Patent Document 1 discloses that a large number of pillars made up of actuators are arranged vertically and horizontally, and the actuators are driven to control the height so that the surface formed by the free ends (vertices) of each pillar has the desired curved shape. A flexible mat is then connected to cover the surface, and the surface of the flexible mat is formed into any curved surface. This curved surface can then be used as a formwork to mold concrete, plaster, etc. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] US Patent Application Publication No. 2013 / 0299084 [Non-patent literature]

[0006] [Non-Patent Document 1] Popescu, Mariana, et al. "Structural design, digital fabrication and construction of the cable-net and knitted formwork of the KnitCandela concrete shell." Structures. Vol. 31. Elsevier, 2021. [Non-patent document 2] Veenendaal, Diederik, and Philippe Block. "Design process for prototype concrete shells using a hybrid cable-net and fabric formwork." Engineering structures 75 (2014): 39-50. Summary of the Invention [Problem to be solved by the invention]

[0007] However, in the method described in Patent Document 1, the actuators that make up each support pillar need to be controlled by precision machinery, making it unsuitable for handling materials that are prone to mechanical failure due to powder (such as cement) or materials that require heating (such as glass). As such, the construction of curved panels is difficult and costly to produce, so it remains a design project and has not been realized as a mass production model. Furthermore, when manufacturing large quantities of one-off, double-curved formwork, there is also the problem of generating a large amount of waste formwork after casting. Despite the increasing demand for complex shapes, this is causing an increased burden on factories and a shortage of craftsmen.

[0008] The present invention has been made in consideration of the above circumstances, and aims to enable the manufacturing of panels with complex curved shapes, such as double-curved shapes, using reusable formwork, thereby reducing the workload and suppressing the generation of waste materials. [Means for solving the problem]

[0009] The method for manufacturing a curved panel of the present invention includes preparing a flexible sheet through which a plurality of wires are inserted so as to be movable in the vertical and horizontal directions and in the lengthwise direction, and having an area larger than the projected area of ​​the desired curved panel when unfolded, and multiple pairs of vertically expandable and contractible support posts that support both ends of the wires pulled out from the periphery of the flexible sheet and hold each wire in a spanning state; The curved panel is manufactured by going through a formwork forming process in which the inside of the flexible sheet is held in a predetermined curved shape to form one side of the curved panel while adjusting at least one of the upper end positions of the supports and the length and tension of the wire between the supports, and a mortar depositing process in which mortar is deposited on the flexible sheet held in the predetermined curved shape, and the mortar is solidified.

[0010] A curved panel is manufactured by forming a curved shape using a flexible sheet supported by wires on vertically extendable supports, and then piling mortar on the flexible sheet as a formwork. In this case, the flexible sheet has an area larger than the projected area of ​​the desired curved panel when unfolded. This allows the curved panel to be manufactured inside the flexible sheet surrounded by the supports. Furthermore, by adjusting at least one of the upper end positions of the supports, the length and tension of the wire, the curved panel of the desired shape can be manufactured, thereby reducing the workload. Furthermore, because the flexible sheet is supported by supports that can expand and contract vertically, the supports, wire, and flexible sheet can be reused by removing the curved panel after the mortar has solidified. This makes it possible to manufacture curved panels of different shapes by adjusting the height of the supports, the length and tension of the wire, and reduces the generation of waste materials.

[0011] In the method for manufacturing a curved panel of the present invention, the formwork forming step includes an optimum value calculation step of calculating optimum values ​​for the height of the support pillars, the length and tension of the wire between the support pillars, according to the shape of the curved panel, using a computer, and a formwork constructing step of setting the flexible sheet to the optimum values ​​obtained in the optimum value calculation step and bridging the flexible sheet between the support pillars, The optimum value calculation step includes: a temporary form setting step of setting a predetermined region of a wire model consisting of a plurality of wire lines simulating a flexible sheet through which the wires are inserted into a temporary form shape having the same coordinates as a target curved panel; a temporary design value calculation step of calculating temporary coordinates of the wire model when the temporary form shape is set, the height of the end points of the wire lines, and temporary design values ​​of the length and tension of the wire line between the end points; a post-load design value calculation step of calculating post-load coordinates of the wire model after deformation by adding a load of a load such as mortar on the region where the temporary form shape is set; a difference calculation step of calculating a difference between the post-load coordinates and the coordinates when set to the temporary form shape; a design value adjustment step of adjusting the height of the end points of the wire line, the length and tension of the wire line between the end points so that the post-load coordinates of the wire model in a state where the load is applied match the coordinates of the temporary form shape based on the difference; and an optimal value determination step of setting the height of the end points of the wire line, the length and tension of the wire line between the end points after adjustment in the design value adjustment step to optimal values ​​for the height of the support pillar, the length and tension of the wire line between the support pillars. It has.

[0012] In the method for manufacturing a curved panel of the present invention, at least a portion of the mortar may be a fiber-mixed mortar containing short reinforcing fibers mixed in. It is also preferable that a plurality of reinforcing sheets such as metal meshes are embedded in the layer formed by the mortar.

[0013] The transformable formwork of the present invention comprises a flexible sheet through which multiple wires are inserted so as to be freely movable vertically, horizontally and longitudinally, and which has an area larger than the projected area of ​​the desired curved panel when unfolded; multiple pairs of vertically extendable pillars which support both ends of the wires pulled out from the periphery of the flexible sheet and hold each wire in a spanning state; a wire support mechanism which can adjust the tension of the wires when spanning between the pillars; and a computer which can calculate the height position of the upper ends of the pillars, the length and tension of each wire in accordance with the shape of the desired curved panel for the area inside the flexible sheet.

[0014] In the flexible formwork of the present invention, the computer a temporary form setting means for setting a predetermined region of a wire model consisting of a plurality of wire lines simulating a flexible sheet through which the wires are inserted into a temporary form shape having the same coordinates as a target curved panel; a temporary design value calculation means for calculating temporary coordinates of the wire model when the temporary form shape is set, the height of the end points of the wire lines, and temporary design values ​​of the length and tension of the wire line between the end points; a post-load design value calculation means for calculating post-load coordinates of the wire model after deformation by adding a load of a load such as mortar on the region where the temporary form shape is set; The system includes a difference calculation means for calculating the difference between the post-load coordinates and the coordinates when set to the temporary formwork shape, a design value adjustment means for adjusting the height of the end points of the wire line, the length and tension of the wire line between the end points so as to align the post-load coordinates of the wire model in a state where the load is applied with the coordinates of the temporary formwork shape based on the difference, and an optimal value determination means for setting the height of the end points of the wire line, the length and tension of the wire line between the end points after adjustment in the design value adjustment step to optimal values ​​for the height of the support, the length and tension of the wire line between the support. [Effects of the Invention]

[0015] According to the present invention, it is possible to manufacture panels with complex curved shapes, such as double curved shapes, using reusable formwork, thereby reducing the workload and suppressing the generation of waste materials. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a perspective view showing an example of a building manufactured by a manufacturing method according to an embodiment of the present invention. [Figure 2] FIG. 2 is a plan view of FIG. [Figure 3] FIG. 2 is a perspective view showing one of the curved panels used in the roof of FIG. 1. [Figure 4] FIG. 1 is a plan view of a deformable formwork according to one embodiment. [Figure 5] FIG. 5 is a front view of the deformable formwork of FIG. 4. [Figure 6] 5A and 5B are enlarged views of a main part of the flexible sheet in FIG. 4, where (a) is a plan view and (b) is a vertical cross-sectional view. [Figure 7] 6A and 6B are enlarged views showing the wire fixture and the wire support mechanism in FIG. 5, where (a) shows the wire fixture and (b) shows the tension adjustment mechanism and the wire fixture. [Figure 8] FIG. 2 is a hardware configuration diagram of a computer used in the manufacturing method of the embodiment. [Figure 9] FIG. 1 is a perspective view showing a schematic diagram of a wire model handled in a computer. [Figure 10] 10 is a flowchart showing an optimum value calculation step in the manufacturing method of one embodiment. [Figure 11] FIG. 10 is a cross-sectional view showing a state in which a panel mortar layer is deposited on a flexible sheet. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0018] [Double curved panel shape] Curved panels 1A to 1H manufactured by the manufacturing method of one embodiment are curved panels used for the roof 3 of the building 2 shown in Fig. 1. The "curved surface" referred to here refers to a curved surface including a single curved surface, a twisted surface, and a double curved surface. This building 2 has a double-curved roof 3 supported by an arched frame 5 on a base 4, and the eight curved panels 1A-1H that make up the roof 3 are the curved panels of this embodiment. As shown in FIG. 2, these curved panels 1A-1H are arranged in a circumferential direction on the top of the building 2. These eight curved panels 1A-1H are approximately the same size, but are formed to have mutually different shapes, either in terms of their outer shape or the curved surface shape of their surfaces. In the example shown in FIG. 2, curved panel 1A is formed line-symmetrically with curved panel 1H, curved panel 1B is formed line-symmetrically with curved panel 1C, curved panel 1D is formed line-symmetrically with curved panel 1E, and curved panel 1F is formed line-symmetrically with curved panel 1G. 3, a rib portion 7 that is thicker than the central portion 6 is formed on the periphery of each of the curved panels 1A to 1H. The rib portion 7 is disposed on the underside of the roof 3. In one embodiment, the manufacturing method is a method of manufacturing the eight curved panels 1A to 1H one panel at a time using one deformable formwork 10.

[0019] [Configuration of flexible formwork] As shown in Figures 4 and 5, the transformable formwork 10 comprises, for example, a rectangular frame-shaped base 11, a plurality of vertically extendable and contractible support columns 12 erected on the base 11, a flexible sheet 14 with a plurality of wires 13 passing vertically and horizontally, a wire support mechanism 15 that spans each of the wires 13 of the flexible sheet 14 between a pair of opposing support columns 12 and fixes them in a state in which the tension of the wires is adjustable, and a computer 16 that can calculate the height position of the upper ends of the support columns 12, the length and tension of each wire 13 according to the shape of the desired curved panels 1A to 1H.

[0020] In the illustrated example, the base 11 is formed in a square frame shape, and for example, thirteen support columns 12 are erected along each of the four sides of the base 11. The shape of the base 11 is not limited to the illustrated example, but is set so that the area surrounded by each support column 12 is a planar area larger than the projected area of ​​the desired unfolded shape of the curved panels 1A-1H. More specifically, the flexible sheet 14 supported by each support column 12 is set so as to be even larger than the projected area of ​​the unfolded shape of the largest curved panel among the unfolded shapes of the curved panels 1A-1H. The number of support columns 12 is also not limited and can be determined depending on the curved surface shape of the curved panels 1A-1H. For simple curved surfaces, fewer support columns 12 are required, but for complex double-curved surfaces, a larger number of support columns 12 is recommended so that the flexible sheet 14 can form a curved surface corresponding to the curved surface shape.

[0021] Alternatively, the number of wires 13 may be adjusted without changing the number of support posts 12. For example, wires 13 may be strung across all support posts 12 (the pitch at which the support posts 12 are erected becomes the pitch of the wires 13), or wires 13 may be strung across support posts 12 at intervals of every other wire 13 (the number of wires 13 is halved and the pitch is doubled).

[0022] Each pillar 12 is formed, for example, in the shape of a double cylinder, with the inner pillar 12B housed within the outer pillar 12A so as to be freely movable in the length direction (vertical direction), and with the lower end of the inner pillar 12B housed within the outer pillar 12A, the upper end of the inner pillar 12B is positioned higher than the upper end of the outer pillar 12A. Also, a drive unit (not shown) using hydraulic pressure, pneumatic pressure, etc. is built into the outer pillar 12A, making it possible to adjust the height position of the upper end of the inner pillar 12B from the upper end of the outer pillar 12A (i.e., the height position of the pillar 12). A linear actuator can be effectively used as this pillar 12. Each support 12 has a hole 17 formed therein into which a fixing device such as a pin can be attached to fix the inner column body 12B to the outer column body 12A, so that the inner column body 12B can be fixed at any height position.

[0023] Furthermore, a pulley 18 is provided at the upper end of each support pillar 12 for suspending wire 13 drawn out from flexible sheet 14, as will be described later. Although pulleys 18 are shown only on a pair of opposing support pillars 12 as a representative example in Fig. 4, pulleys 18 are provided at the upper ends of all support pillars 12. These pulleys 18 are supported in the same direction at the upper ends of each support pillar 12 on two opposing sides (two parallel sides of base 11) at the periphery of base 11 so that wire 13 can be stretched between support pillars 12 erected on these two opposing sides. In other words, in the support pillars 12 erected on two sides along the Y direction in Figure 4, the wires 13 are arranged along the X direction, and in the support pillars 12 erected on two sides along the X direction in Figure 4, the orientation of each pulley 18 is aligned so that the wires 13 can be arranged along the Y direction.

[0024] As shown in FIG. 6, the flexible sheet 14 is formed by overlapping two approximately square stretchable membranes 21 and sewing them together, forming a lattice-like, bag-like tubular portion 22 for inserting the wires 13. The stretchable membranes 21 are made of, for example, polyester resin. The tubular portion 22 has an inner diameter of, for example, approximately 6 mm and an outer diameter of, for example, approximately 3 mm, through which the wires 13 are inserted. The tubular portion 22 is formed between the sewn portions 23 by sewing two parallel points on the membrane 21. The lattice intersections 24 are formed by sewn together, for example, within an 8 mm x 8 mm area, where the wires 13 intersect. In the illustrated example, 13 vertical and 13 horizontal wires 13 are used, resulting in 169 intersections 24. Therefore, by supporting the flexible sheet 14 on the support posts 12 and adjusting the length and tension of each wire 13 between the support posts 12, the curved shape of the flexible sheet 14 can be changed.

[0025] Furthermore, since flexible sheet 14 is used as a formwork to support the lower portion when depositing mortar, it is made of a material that can deposit mortar. Furthermore, to allow for the deposition of mortar to form curved panels 1A-1H, flexible sheet 14 is formed to be larger than projected area Q of the unfolded shape of the largest curved panel among curved panels 1A-1H, as shown by the two-dot chain line in Figure 4.

[0026] In conventional cable net construction methods using wires, the wires are joined at their intersections with metal fittings, meaning that each wire is restricted and unable to move freely. As a result, when adjusting the length of the wires, it is necessary to loosen the metal fittings, make the necessary adjustments, and then refasten the metal fittings, which is extremely cumbersome. In this embodiment, each wire 13 can move slightly not only in the longitudinal direction but also in the left-right direction within the tubular portion 22, and even at the lattice intersections 24, the wires 13 can move within a predetermined range without being restricted by each other.

[0027] Both ends of each wire 13 are pulled outward from the four sides of the flexible sheet 14, and are fixed by a wire support mechanism 15 while suspended from pulleys 18 at the upper ends of each support column 12. The wire support mechanism 15 includes a bracket 31 provided midway along the height of the outer column body 12A of the support column 12 so as to follow each side of the quadrangle in which the support columns 12 are arranged, and a wire fixture 32 and tension adjustment mechanism 33 provided on the bracket 31 for each support column 12. In this case, the bracket 31 is made of, for example, an angle bar, and is fixed to the outer surface of the support 12 along these sides so as to be positioned outside the quadrangle formed by the support 12. As shown in Figure 7, the wire fixture 32 securely fastens one end of the wire 13 to the bracket 31, and is made of, for example, a bolt and nut fastener, and the tension adjustment mechanism 33 is made of, for example, a turnbuckle. This tension adjustment mechanism 33 is provided on only one of the fixed ends of the wire 13.

[0028] Specifically, one end of the wire 13 is fixed to a wire fixture 32 on a bracket 31 of one of two supports 12 arranged opposite two parallel sides of a quadrangle formed by the supports 12, and the wire 13 passes through a pulley 18 at the top end of the support 12 and is fixed to the bracket 31 of the other support 12 by the wire fixture 32, with a tension adjustment mechanism 33 interposed therebetween. By adjusting this tension adjustment mechanism 33, the length and tension of the wire 13 stretched between both supports 12 can be adjusted, and the length (or height position) and tension of the wire 13 between the supports 12 can be adjusted.

[0029] In this way, the wires 13 drawn out from each cylindrical portion 22 on the periphery of the flexible sheet 14 are fixed to the brackets 31 via the pulleys 18 of the support posts 12, and the length and tension of the wires 13 between the two support posts 12 can be adjusted by each tension adjustment mechanism 33. Furthermore, the height position of each support post 12 itself, in other words, the height position of the pulleys 18, can be moved up and down, and by appropriately adjusting the length and tension of the wires 13 and the height position of the support posts 12, each wire 13 can be arranged in any desired shape, and by appropriately adjusting each of the wires 13 arranged in a grid pattern, the flexible sheet 14 supported by the wires 13 can be formed into any desired shape. A predetermined area inside the flexible sheet 14 is used as a mold for forming the curved panels 1A to 1H.

[0030] As shown in Fig. 8, the computer 16 for controlling the shape of this formwork comprises a CPU (Central Processing Unit) 41, memory 42, storage device 43, input interface 44, output interface 45, communication interface 46, etc., which are connected to each other via a bus 47 so that data can be transmitted between them. When a signal is input from an input device 48 such as a keyboard, touch panel, or mouse via the input interface 44, the program and control data stored in the storage device 43 are called up into the memory 42 based on the input data, and the CPU 41 operates in accordance with the program to perform various calculations and outputs signals from the output interface 45 to an output device 49 such as a display or printer.

[0031] Furthermore, signals can be sent and received to and from an external device 50 via the communication interface 46. For example, a height sensor that measures the height of the support 12 can be provided, and the height sensor and the drive unit of the actuator that constitutes the support 12 can be used as the external device 50. Signals can be sent and received to and from this external device 50 via the communication interface 46, and a control signal can be sent to the drive unit of the support 12 while providing feedback via the height sensor, thereby controlling the up and down movement of the support 12.

[0032] The CPU 41 uses a wire model 55 as shown in FIG. 9, which assumes that the wires 13 embedded in the flexible sheet 14 are specific springs, and while analyzing the shape of the wire model 55 and its behavior due to mortar deposition, determines the shape of the wire model 55 constructed using a specified area as a formwork, and determines the length, tension, and end position (position of the pulley 18 of the support 12) of each wire 13.

[0033] In this case, flexible sheet 14 has an area larger than projection area Q when target curved panels 1A-1H are unfolded, and wires 13 extend from its four sides. Wires 13 are supported by pulleys 18 on support columns 12. Therefore, wire model 55 handled by computer 16 has wire lines 56 corresponding to wires 13, and the portions supported by pulleys 18 on support columns 12 are defined as end points 57 of each wire line 56 in wire model 55. A form area 58 corresponding to the aforementioned projection area Q is set inside flexible sheet 14. End points 57 of wire lines 56 in wire model 55 are located outside form area 58, and their positions in the X and Y directions are fixed, but they are movable only in the Z direction (height direction). The shape of wire model 55 is determined by the coordinates (x, y, z) of intersections 59 of each wire line 56. Then, while analyzing the behavior of the wire model 55, the height (coordinates) of the end points 57 of each wire line 56, the length of the wire line 56 between the end points 57, and the tension of the wire line 56 are calculated to form a formwork for manufacturing the curved panels 1A to 1H.

[0034] [Formwork formation method] Below, using curved panel 1A as an example, a method for forming a formwork for manufacturing curved panel 1A includes an optimal value calculation process in which a computer is used to calculate optimal values ​​for the height of the support pillars, the length and tension of the wire between the support pillars according to the shape of the curved panel, and a formwork construction process in which a flexible sheet is set to the optimal value obtained in the optimal value calculation process and stretched across the support pillars.

[0035] The optimum value calculation process includes a temporary form setting process for setting a predetermined area of ​​a grid-line wire model 55 consisting of a plurality of wire lines 56 simulating the flexible sheet 14 through which the wires 13 are inserted, into a temporary form shape with the same coordinates as the target curved panel 1A; a temporary design value calculation process for calculating temporary coordinates of intersections 59 of the wire model 55 when the temporary form shape is set, the height of end points 57 of the wire lines 56, and temporary design values ​​of the length and tension of the wire lines 56 between the end points 57; and a post-load setting process for calculating post-load coordinates of the wire model 55 after it has been deformed by adding a load of a load such as mortar to the area where the temporary form shape has been set. a design value adjustment process for adjusting the height of end points 57 of the wire line 56, the length and tension of the wire line 56 between the end points 57 so that the post-load coordinates of the wire model 55 in a loaded state match the coordinates of the temporary formwork shape based on the difference; and an optimal value determination process for setting the height of end points 57 of the wire line 56, the length and tension of the wire line 56 between the end points 57 after adjustment in the design value adjustment process to the optimal values ​​of the height of the pillars 12, the length and tension of the wire 13 between the pillars 12. The steps will be explained below in order. Since this optimum value calculation process is performed by the computer 10, the means for realizing the function of the computer 10 is also listed for each process.

[0036] (Temporary form setting process: temporary form setting means) A mold region 58 of the outline corresponding to the area Q obtained by developing and projecting the curved shape of the target curved panel 1A is determined inside the planar wire model 55. In this process, when the worker inputs the curved shape of the curved panel 1A through the input device 48, the CPU 41 develops the curved shape into a planar shape and sets this as the mold region 58 in the wire model 55. Alternatively, the worker may calculate in advance the area obtained by developing and projecting the curved shape, and then input the calculated value through the input device 48 to set it in the wire model 55. Each wire line 56 corresponds to a wire 13. Then, both ends of each wire line 56 in the wire model 55 are extended to determine an end point 57. This end point 57 corresponds to the position of the pulley 18 of the support 12, and corresponds to the position of the support 12 of the transformable formwork 10. The X and Y coordinates are fixed and determined, and only the Z coordinate can be changed.

[0037] Next, wire model 55 is deformed so that the inner shape of previously determined form area 58 becomes the desired curved shape, and the height positions (Z coordinates) of end points 57 and the length of wire line 56 between both end points 57 are determined to create wire model 55 as shown in Figure 9. Wire model 55 here is not the final shape but a temporary wire model (provisional wire model). Form area 58, which corresponds to the area onto which the unfolded shape of curved panel 1A is projected, is shown by a two-dot chain line.

[0038] (Provisional design value calculation step: Provisional design value calculation means) Each intersection 59 of this wire model 55 becomes a coordinate (called a provisional coordinate) that matches the curved shape of the curved panel 1A, and the provisional coordinates, the coordinates of the end points 57 of each wire line 56 at that time, and the length and tension of the wire line 56 between the end points 57 are calculated and stored in the memory device 43.

[0039] (Post-load design value calculation process: Post-load design value calculation means) Next, a structural analysis of the deflection of the wire model 55 is performed by applying a load equivalent to the weight of the mortar used to construct the curved panel 1A and the weight of a panel frame 61 and a panel mortar layer 62 (described later) to the formwork area 58, and the coordinates (post-load coordinates) of each intersection 59 of the wire model 55 (hereinafter referred to as the post-load wire model) after the load is applied, as well as post-load design values ​​such as the length and tension of the wire line 56 are calculated. At this time, the load not only acts directly on the formwork area 58, but also on the wire line 56 surrounding the formwork area 58. Therefore, the deflection is analyzed while identifying the wire line 56 on which the load acts directly and the surrounding wire line 56. Note that the position of the end point 57 of the wire line 56 is not changed and remains at the initial setting.

[0040] (Difference calculation process: difference calculation means) The difference (amount of change) between the post-load coordinates and the previously determined temporary coordinates in this formwork area 58 is calculated. This difference corresponds to the deflection due to the weight of the mortar and panel frame 61.

[0041] (Design value adjustment process: design value adjustment means) Then, in the wire model 55 with this load applied, the position (height) of the end point 57 of each wire line 56, the length of the wire line 56 between the end points 57, and the tension are calculated so as to reduce the difference between the post-load coordinates and the temporary coordinates. The temporary coordinates are coordinates that match the shape of the desired curved panel 1A, and reducing the difference between the post-load coordinates and the temporary coordinates means that the formwork area 58 of the wire model 55 in the post-load coordinates is aligned with the shape of the curved panel 1A. However, the tension of the wire line 56 is the tension when a load is applied.

[0042] The task of reducing this coordinate difference is performed at the coordinates of each intersection 59 of the wire model 55, but changing the coordinate of a specific intersection means adjusting the two wire lines 56 that make up that coordinate, and because the coordinates of multiple intersections are related to those two wire lines 56, it is difficult to adjust the coordinates of all of the intersections 59 at once. For this reason, this adjustment (calculation) is repeated multiple times while calculating the difference (amount of change) from the provisional coordinates so as to minimize the difference in coordinates of each intersection 59 as much as possible.

[0043] (Optimal value determination step: optimal value determination means) After repeating the difference calculation process and the design value adjustment process multiple times, when the coordinates of the formwork area 58 of the wire model 55 approximately match the shape (temporary coordinates) of the curved panel 1A, the position (height) of the end points 57 of each wire line 56, the length of the wire line 56 between the end points 57, and the tension are calculated as optimal values. The position (height) of the end point 57 of each wire line 56 obtained in this way is the height of the support 12 (height position of the pulley 18), the length of the wire line 56 between the end points 57 is the length of the wire 13 between the pulleys 18, and the tension is the tension of the wire 13.

[0044] The above steps from the temporary formwork setting process to the optimal value determination process can be performed using, for example, the physics calculation software Karamba and Kangaroo, which are plug-ins for the 3D application Rhinoceros (registered trademark) + the graphical algorithm editor Grasshopper. The shape of the wire before and after the load is estimated using this physics calculation analysis software Kangaroo. The wire model 55 thus formed is input into the structural analysis plug-in Karamba, which estimates the shape of the wire that will be deformed by the load. The difference between the shape obtained by the analysis and the target surface is calculated, and the position of the wire's endpoints and the tension are changed to reduce the difference. This process is repeated to minimize the difference. In practice, these programs are used to construct a program that minimizes the difference between the form shape and the target curved surface shape, which is stored in the storage device 43 and then called up for processing.

[0045] [Concrete formwork construction work] Next, based on the data thus obtained, concrete formwork construction work is carried out in the actual transformable formwork 10. The outline (formwork area) of the desired unfolded curved panel 1A is marked on the flexible sheet 14, and while passing the wire 13 through each tubular portion 22 of the flexible sheet 14, or after passing the wire 13 through the tubular portions 22, the wire 13 is supported on the pulleys 18 of the supports 12 of the deformable formwork 10, and the height of the supports 12, the length and tension of the wire 13 are set to the optimum values ​​obtained, thereby forming a formwork shape for layering mortar inside the flexible sheet 14.

[0046] When adjusting the tension of the wires 13, for example, tension may be applied to the wires 13 arranged in the X direction starting from the ends, and then similarly applied to the wires 13 arranged in the Y direction; or tension may be applied to the wires 13 arranged in the X direction starting from the center toward both ends, and then similarly applied to the wires 13 arranged in the Y direction starting from the center toward both ends; or the wires 13 arranged in the X direction may be relaxed to a predetermined length, and tension may be applied to the wires 13 arranged in the Y direction starting from the center toward both ends, and then tension may be applied to the wires 13 arranged in the X direction starting from the center toward both ends. Any appropriate method may be used.

[0047] Once the deformable formwork 10 has been constructed to fit the curved panel 1A in the manner described above, the curved panel 1A is formed on the marked area of ​​the flexible sheet 14. The curved panel 1A is composed of a panel frame 61 that forms its outer shape and an inner panel mortar layer 62. The panel frame 61 is formed into a frame shape from a flexibly deformable material such as polystyrene resin, and is deformed on the flexible sheet 14 to fit the surface shape of the flexible sheet 14. Then, a panel frame 61 is placed on the marked area of ​​the flexible sheet 14, and a panel mortar layer 62 is formed inside the panel frame 61 as follows.

[0048] [Panel mortar layer composition] 11 shows the state in which the panel mortar layer 62 is formed on the flexible sheet 14, and includes an inner surface finishing layer 63, a fiber reinforced mortar layer 64 laminated on the inner surface finishing layer 63, and an outer surface finishing layer 65 covering the outer surface of the fiber reinforced mortar layer 64. Each layer will be described in detail below.

[0049] (Inner surface finish layer) The inner surface finishing layer 63 is a layer facing the interior space of the building 2, and is formed by a mortar layer, a plaster layer, or the like.

[0050] (fiber reinforced mortar layer) The fiber reinforced mortar layer 64 is a layer in which mortar and short reinforcing fibers are mixed, and although there are no particular limitations on the overall thickness, it is formed to be 5 mm or more and 50 mm or less.

[0051] Mortar is a mixture of cement, fine aggregate, and water. The mixture may contain admixtures such as silica fume, slag, fly ash, and dolomite, as well as shrinkage-reducing agents, water-reducing agents, and other additives.

[0052] The cement that can be used includes ordinary Portland cement, early-strength Portland cement, extra-early-strength Portland cement, moderate-heat Portland cement, low-heat Portland cement, sulfate-resistant Portland cement, ordinary Portland cement (low alkali type), early-strength Portland cement (low alkali type), and extra-early-strength Portland cement (low alkali type) as specified in JIS R 5210. Low-alkali cements other than JIS R 5210 may also be used.

[0053] Admixtures such as silica fume, slag, fly ash, and dolomite may also be included. Fiber-mixed mortar may also contain shrinkage-reducing agents, water-reducing agents, and other additives. Examples of water-reducing agents include naphthalene sulfonate-formalin high condensate salts and polycarboxylic acid ether compounds, and shrinkage-reducing agents include alkylene oxide compounds of lower alcohols.

[0054] The reinforcing short fibers are not limited to any particular material, but may be glass, carbon, or steel fibers, and preferably are chopped strands made by bundling multiple fibers together. Chopped strands are obtained by cutting roving into predetermined lengths of 6.0 mm, 9.0 mm, 13.0 mm, 19.0 mm, or 25.0 mm, and are preferably made of alkali-resistant AR glass fibers (JIS R3410) containing 16% or more of zirconia.

[0055] (exterior finishing layer) The exterior finish layer 65 forms the outer surface of the roof. It is typically a layer of cement, fine aggregate, and water (mortar) mixed together without short fibers for mortar reinforcement, hardened into a smooth surface. This mixture may contain admixtures such as silica fume, slag, fly ash, and dolomite, as well as shrinkage-reducing agents, water-reducing agents, and other additives. Like fiber-mixed mortar, it uses cement, fine aggregate, and water, but these proportions may be the same or different. Admixtures and additives may or may not be included. If these are included, the cement, fine aggregate, water, admixtures, and additives may be the same as those in fiber-mixed mortar, or they may be different.

[0056] In this case, even if some of the mixed short fibers protrude from the surface of the fiber-reinforced mortar layer 64, the outer surface can be finished smoothly by forming the outer surface finishing layer 65 on top of them. If necessary, the outer surface finishing layer 65 may be made of tiles or the like.

[0057] (Panel mortar layer formation process) Next, a method for manufacturing the panel mortar layer 62 configured as above will be described. This panel mortar layer 62 is constructed by depositing a plurality of mortar layers in a stacked state inside a panel frame 61 placed in the formwork area Q of the flexible sheet 14. First, an inner surface finishing layer 63 of a predetermined thickness (for example, a thickness of 0.5 mm to 30 mm) is formed using mortar on the flexible sheet 14. This mortar is applied by spraying using a mortar gun, or by a hand lay-up method in which a worker deposits the mortar to the predetermined thickness using a trowel or the like.

[0058] Next, a fiber-reinforced mortar layer 64 containing mortar and short fibers is formed to a predetermined thickness on the inner surface finishing layer 63. This fiber-reinforced mortar layer 64 can be formed by a method such as a direct spray method or a hand layup method. For example, in the direct spray method, mortar containing no short fibers is sprayed with a mortar gun, and at the same time, short fiber rovings are cut and sprayed together with the atomized mortar slurry with a spray gun, thereby forming a fiber-reinforced mortar layer 64 containing a mixture of mortar and short fibers. Furthermore, when forming the fiber-reinforced mortar layer 64 by the hand layup method, a short-fiber-mixed mortar in which short fibers cut to a predetermined length in advance are mixed into the mortar is used (premix method), and an operator deposits the mortar to a predetermined thickness using a trowel or the like. If necessary, multiple reinforcing sheets made of continuous fiber reinforcement material formed by weaving or knitting alkali-resistant long fibers such as glass fibers into a mesh pattern may be interposed inside the fiber-reinforced mortar layer 64. In this case, the reinforcing sheets and short-fiber mixed mortar may be alternately layered so that the short-fiber mixed mortar fills the gaps between the reinforcing sheets.

[0059] Finally, an outer surface finishing layer 65 made of mortar or the like that does not contain short fibers is formed on the fiber-reinforced mortar layer 64. Even if some of the short fibers protrude from the fiber-reinforced mortar layer 64, by forming this outer surface finishing layer 65, the short fibers are embedded in the outer surface finishing layer 65, and the surface of the outer surface finishing layer 65 is finished to a smooth surface. In addition, the mortar is made thicker at the peripheral edge than at the central portion 6 to form a rib portion 7. After the mortar has cured, the panel frame 61 is removed from above the flexible sheet 24, and then the panel mortar layer 62 is removed, thereby producing the curved panel 1A.

[0060] The curved panel 1A manufactured as described above has the fiber reinforced mortar layer 64, and therefore has excellent strength despite its thinness. In addition, on the surface (back surface) of the curved panel 1A that was in contact with the flexible sheet 14, the traces of the wires 13 in the flexible sheet 14 are transferred in a grid pattern as linear depressions, and the bulging convex portions between the traces of the wires 13 are aligned vertically and horizontally, creating a pattern.

[0061] After curved panel 1A is removed, flexible sheet 14 can be formed into a different curved surface by changing the length and tension of wires 13 and the height of support posts 12. In the present embodiment, multiple types of curved panels 1A to 1H are provided, and flexible sheet 14 is set to be larger than the projection area Q of the largest shape among the unfolded shapes of curved panels 1A to 1H. Therefore, after one curved panel is manufactured and removed, another curved panel can be manufactured using the same procedure as above.

[0062] In each of the above embodiments, the present invention is applied to a curved panel that constitutes the roof of a building, but the present invention is not limited to this and can be applied to curved panels that constitute various structures, including walls and floors. In addition, in the embodiment, the wire 13 is supported by the pulley 18 on the support 12, but it is not limited to a pulley as long as it can support the wire. Rotatable rollers or non-rotatable rollers can also be used instead of pulleys. In addition, the structure of the support pillars is not limited to that of the embodiment, and can be modified as appropriate within the scope of the present invention. [Explanation of symbols]

[0063] 1A~1H Curved panel 2 Buildings 3. Roof 4 Foundation 5 frames 6 Central part 7 Rib section 10. Flexible formwork 11. Base 12 pillars 12A Outer column 12B Inner column 13 wires 14 Flexible Sheet 15 Wire support mechanism 16 Computer 17 holes 18 Pulley 32 Wire Fixture 33 Tension adjustment mechanism 55 Wire Model 56 Wire Line 57 End point coordinates 58 Formwork Area 59 Intersection coordinates 61 Panel Frame 62 Panel mortar layer 63 Inner surface finish layer 64 Fiber-reinforced mortar layer 65 Outer surface finishing layer

Claims

1. A flexible sheet through which a plurality of wires are inserted so as to be movable in the vertical and horizontal directions and which has an area larger than the projected area of ​​the desired curved panel when unfolded, and a plurality of pairs of vertically expandable and contractible support posts which support both ends of the wires drawn out from the periphery of the flexible sheet and hold each wire in a bridging state, are provided; A method for manufacturing a curved panel, characterized by comprising a formwork forming process for holding the inside of the flexible sheet in a predetermined curved shape for forming one side of the curved panel while adjusting at least one of the upper end positions of the supports and the length and tension of the wire between the supports, and a mortar depositing process for depositing mortar on the flexible sheet held in the predetermined curved shape, and then producing the curved panel by solidifying the mortar.

2. The form forming step includes an optimum value calculation step of calculating optimum values ​​for the height of the support pillars, the length and tension of the wire between the support pillars, according to the shape of the curved panel, using a computer, and a form constructing step of setting the flexible sheet to the optimum values ​​obtained in the optimum value calculation step and bridging the flexible sheet between the support pillars, The optimum value calculation step includes: a temporary form setting step of setting a predetermined region of a wire model consisting of a plurality of wire lines simulating a flexible sheet through which the wires are inserted into a temporary form shape having the same coordinates as a target curved panel; a temporary design value calculation step of calculating temporary coordinates of the wire model when the temporary form shape is set, the height of the end points of the wire lines, and temporary design values ​​of the length and tension of the wire line between the end points; a post-load design value calculation step of calculating post-load coordinates of the wire model after deformation by adding a load of a load such as mortar on the region where the temporary form shape is set; a difference calculation step of calculating a difference between the post-load coordinates and the coordinates when set to the temporary form shape; a design value adjustment step of adjusting the height of the end points of the wire line, the length and tension of the wire line between the end points so that the post-load coordinates of the wire model in a state where the load is applied match the coordinates of the temporary form shape based on the difference; and an optimal value determination step of setting the height of the end points of the wire line, the length and tension of the wire line between the end points after adjustment in the design value adjustment step to optimal values ​​for the height of the support pillar, the length and tension of the wire line between the support pillars. The method for manufacturing a curved panel according to claim 1, further comprising:

3. 2. The method for manufacturing a curved panel according to claim 1, wherein at least a part of the mortar is a fiber-mixed mortar containing short reinforcing fibers.

4. 2. The method for manufacturing a curved panel according to claim 1, wherein a reinforcing sheet is embedded in the mortar in the mortar depositing step.

5. A transformable formwork characterized by comprising: a flexible sheet through which a plurality of wires are inserted so as to be freely movable vertically, horizontally and longitudinally, and having an area larger than the projected area of ​​the desired curved panel when unfolded; multiple pairs of vertically extendable pillars that support both ends of the wires pulled out from the periphery of the flexible sheet and hold each wire in a spanning state; a wire support mechanism that can adjust the tension of the wires in a spanning state between the pillars; and a computer that can calculate the height position of the upper ends of the pillars, the length and tension of each wire in accordance with the shape of the desired curved panel for the inner area of ​​the flexible sheet.

6. The computer a temporary form setting means for setting a predetermined region of a wire model consisting of a plurality of wire lines simulating a flexible sheet through which the wires are inserted into a temporary form shape having the same coordinates as a target curved panel; a temporary design value calculation means for calculating temporary coordinates of the wire model when the temporary form shape is set, the height of the end points of the wire lines, and temporary design values ​​of the length and tension of the wire line between the end points; a post-load design value calculation means for calculating post-load coordinates of the wire model after deformation by adding a load of a load such as mortar on the region in which the temporary form shape is set; and a calculation means for calculating the post-load coordinates of the wire model and the temporary form shape. a design value adjusting means for adjusting the height of the end points of the wire line, the length and tension of the wire line between the end points so that the post-load coordinates of the wire model in a state where the load is applied match the coordinates of the temporary formwork shape based on the difference; and an optimal value determining means for setting the height of the end points of the wire line, the length and tension of the wire line between the end points after adjustment in the design value adjustment step to optimal values ​​for the height of the support pillars, the length and tension of the wire line between the support pillars.

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