Method for manufacturing mortar structures and system for manufacturing mortar structures

Abstract

High-quality mortar structures are formed using a 3D printer. [Solution] The mortar construction manufacturing system 10 includes a discharge mechanism 11 that discharges mortar from a nozzle 15 to form a mortar layer 30, a moving mechanism 12 that moves the nozzle 15, and a spraying mechanism 13 that sprays a curing agent 32 onto the side surface of the mortar layer 30. The manufacturing system 10 stacks the mortar and, in parallel with the stacking, sprays the curing agent 32 onto the stacked mortar. The spraying units 24 and 25 spray the curing agent 32 onto the mortar layer 30 below the stacking mortar layer 30.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a mortar structure formed by laminating mortar or the like, and a system for manufacturing a mortar structure.

Background Art

[0002] When forming a three-dimensional structure, a three-dimensional (3D) printer may be used. This 3D printer causes a moving nozzle to discharge a material to form a mortar layer. Then, a three-dimensional shape is formed by stacking the mortar layers (see, for example, Patent Document 1).

Prior Art Literature

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in order to ensure qualities such as strength, durability, and crack resistance, mortar structures require curing in which the structure is maintained at a temperature and humidity necessary for hardening and protected for a certain period. For example, during the curing period, the mortar structure is covered with a curing mat or the like to perform wet curing.

[0005] In wet curing, it is preferable to perform the curing before moisture dissipates. However, conventionally, since the work of covering the mortar structure with a curing mat is performed after the mortar structure is formed using a 3D (three-dimensional) printer, there is a possibility that the quality may deteriorate as the moisture contained in the mortar structure gradually dissipates. In particular, among the mortar structure, in the lower layer laminated in the initial stage, the progress of hardening and drying is more remarkable than in the upper layer.

Means for Solving the Problems

[0006] A method for manufacturing a mortar structure that solves the above problems involves layering mortar and, in parallel with the layering, spraying a curing agent onto the layered mortar. A mortar structure manufacturing system that solves the above problems comprises a discharge mechanism that discharges mortar from a nozzle and layers the mortar, a moving mechanism that moves the nozzle, and a spraying mechanism that sprays a curing agent onto the mortar in parallel with the layering. [Effects of the Invention]

[0007] According to this disclosure, high-quality mortar structures can be formed using a 3D printer. [Brief explanation of the drawing]

[0008] [Figure 1] This figure shows a schematic diagram of one embodiment of the manufacturing system of the present disclosure. [Figure 2] A block diagram showing the functions of the control device in the same embodiment. [Modes for carrying out the invention]

[0009] This paper describes a method for manufacturing mortar structures using a 3D printer and an embodiment of a mortar structure manufacturing system. [Overview of the manufacturing system for mortar structures] Figure 1 is a schematic diagram of the manufacturing system 10 of this embodiment. The manufacturing system 10 comprises a 3D printer, an extrusion mechanism 11, a moving mechanism 12, a spraying mechanism 13, and a control device 40 (see Figure 2).

[0010] The discharge mechanism 11 includes a nozzle 15, a supply hose 16, a pressure pump (not shown), etc. The nozzle 15 has a discharge port 17 on its lower surface for discharging mortar. The supply hose 16 supplies mortar to the nozzle 15. The mortar is supplied to the nozzle 15 via the supply hose 16 by the drive of the pressure pump and discharged downward from the discharge port 17.

[0011] The moving mechanism 12 includes an arm 18 connected to the nozzle 15, an actuator that drives the arm 18, and a motor that serves as a power source (none of which are shown). The arm 18 is an articulated robot arm with multiple joints, and its movement is controlled by instructions from the control device 40. The control device 40 controls the arm 18 so that the direction of mortar discharge from the nozzle 15 is always vertical (downward) even when moving. With this configuration, the nozzle 15 moves horizontally and vertically according to the movement of the arm 18 controlled by the control device 40. As the discharge mechanism 11 discharges mortar from the nozzle 15 and the moving mechanism 12 moves the nozzle 15, the mortar layer 30 is stacked along a predetermined path.

[0012] The spraying mechanism 13 includes a support member 20 connected to the nozzle 15, spraying sections 24 and 25 provided on the support member 20, a pressure pump (not shown) for pumping the curing agent 32 (paint film curing agent), etc. The support member 20 includes a first support member 21 extending on both sides of the nozzle 15, and a pair of second support members 22 and 23 extending vertically from each end of the first support member 21. The support member 20 moves horizontally and vertically as the nozzle 15 moves.

[0013] The spraying sections 24 and 25 are located to the side of the nozzle 15 and are provided on the second support members 22 and 23, respectively. Each of the spraying sections 24 and 25 has at least one spraying opening 28 and 29. The spraying openings 28 and 29 are located below the discharge opening 17. The spraying sections 24 and 25 are positioned so that their spraying openings 28 and 29 are directed towards the area below the nozzle 15 where a laminate consisting of at least one mortar layer 30 is formed. Hoses 26 and 27 are connected to the ends of the spraying sections 24 and 25 opposite to the spraying openings 28 and 29.

[0014] The curing agent 32 is supplied to the spraying units 24 and 25 via hoses 26 and 27 by the drive of a pressure pump. The spraying units 24 and 25 spray the curing agent 32 onto the sides of the mortar layer 30 from the spraying nozzles 28 and 29. The spraying units 24 and 25 also spray the curing agent 32 onto the mortar layer 30 below the mortar layer 30 being laminated. At this time, since the mortar layer 30 is in a state before hardening, it is preferable for the spraying units 24 and 25 to spray the curing agent 32 in a mist form.

[0015] The curing agent 32 can be any agent capable of suppressing the evaporation of moisture from the mortar. For example, the curing agent 32 can form a film on the surface of the mortar layer 30 or penetrate the mortar layer 30 to seal in moisture inside. For example, as the curing agent 32, liquid agents such as paraffin wax-based agents with paraffin as the main component, hydrochloric silica compound-based agents with silicon chloride as the main component, and wax derivative-based agents can be used. Alternatively, a primer can be used in place of the above-mentioned liquid agents. Suitable primers for the curing agent 32 include, for example, acrylic-methacrylic primers with alkyl acrylate and methacrylic acid as the main components.

[0016] As shown in Figure 2, the control device 40 includes a control unit 41. The control unit 41 includes at least a processor and memory. The processor is a CPU and / or ASIC (Application-Specific Integrated Circuit), and controls each process using programs and data stored in the memory. The memory (computer-readable medium) is a ROM, RAM, hard disk, etc. The control device 40 may also include an input / output interface that transmits and receives signals between the discharge mechanism 11, the moving mechanism 12, and the spraying mechanism 13, and transmits and receives data via a communication network such as the Internet or short-range communication. The control device 40 may also include an input unit and an output unit (not shown). The input unit is a touch panel, keyboard, etc. The output unit is a display, etc.

[0017] The control unit 41 functions as a movement control unit 43, a discharge control unit 44, and a spraying control unit 45 by executing a program. The control device 40 also includes a path memory unit 42. The path memory unit 42 stores path data including the path of the nozzle 15 for forming the mortar structure and the paths of the spraying units 24 and 25. The path data associates the discharge position and stopping position of mortar from nozzle 15 with the spraying position and stopping position of curing agent 32 from spraying units 24 and 25. The path of nozzle 15 indicates the position where the mortar layer 30 is formed. Each of the spraying paths of spraying units 24 and 25 is set to sandwich the path of nozzle 15 when viewed from above, along the path of nozzle 15. In other words, the path of nozzle 15 is set between each of the spraying paths of spraying units 24 and 25. The distance between each of the spraying paths of spraying units 24 and 25 and the path of nozzle 15 is constant or approximately constant. Also, in the vertical direction, the position of the path of nozzle 15 is different from the position of the spraying paths of spraying units 24 and 25. For example, the path of the nozzle 15 for forming the Nth mortar layer 30 is set above the Nth mortar layer 30, but the paths of the spraying units 24 and 25 for forming the Nth mortar layer 30 are set to the side of the Nth mortar layer 30.

[0018] The movement control unit 43 transmits various signals to the movement mechanism 12 and receives various signals from the movement mechanism 12. The movement control unit 43 controls the movement mechanism 12 to move the nozzle 15 along the path indicated by the path data.

[0019] The discharge control unit 44 transmits various signals to the discharge mechanism 11 and receives various signals from the discharge mechanism 11. The discharge control unit 44 controls the discharge of mortar from the nozzle 15 along the path indicated by the path data. For example, the discharge control unit 44 controls the pump that pumps the mortar.

[0020] The spraying control unit 45 transmits various signals and the like to the spraying mechanism 13 and receives various signals from the spraying mechanism 13. The spraying control unit 45 controls the spraying of the curing agent 32 from the spraying units 24 and 25 along the path indicated by the path data. For example, the spraying control unit 45 controls the pump that pressure-feeds the curing agent 32. The spraying control unit 45 sprays the curing agent 32 onto the mortar layer 30 lower than the mortar layer 30 being laminated, in synchronization with the discharge of mortar from the nozzle 15.

[0021] [Method for producing mortar structure] The method for producing a mortar structure will be described. Here, a case where a predetermined number (Nmax) of mortar layers 30 having the same length are laminated will be described.

[0022] The movement control unit 43 controls the movement mechanism 12 to place the nozzle 15 at the start point of the path for forming the mortar layer 30. Further, the movement control unit 43 adjusts the position in the height direction (the direction of arrow Z in FIG. 1) so that a predetermined distance is maintained between the nozzle 15 and the placement surface or the mortar layer 30. Further, the discharge control unit 44 controls the discharge mechanism 11 to start discharging mortar from the nozzle 15.

[0023] The nozzle 15 forms the first mortar layer 30 by moving along the forward direction (the direction of arrow Y in FIG. 1), which is the formation direction of the mortar layer 30, while discharging mortar. In the path data, data for stopping the spraying of the curing agent 32 is associated with the path for forming the first mortar layer 30. Therefore, spraying of the curing agent 32 is not performed when forming the first mortar layer 30.

[0024] After forming the first mortar layer 30, the movement control unit 43 raises the nozzle 15 by a predetermined interval. Then, the movement control unit 43 moves the nozzle 15 along the reverse direction (the direction opposite to arrow Y), which is the direction opposite to the forward direction, to form the second mortar layer 30 on the first mortar layer 30.

[0025] When the nozzle 15 forms the second layer of mortar 30, the spraying control unit 45 controls the spraying units 24 and 25 based on path data to spray the curing agent 32 onto the side surface of the first layer of mortar 30. At this time, the distance between the spraying nozzles 28 and 29 and the side surface of the mortar layer 30 is maintained constant.

[0026] In other words, in the path data, the path of the second mortar layer 30 is associated with the spraying path of the curing agent 32 (or spraying section 24, 25) to the first mortar layer 30. This allows the formation of the second mortar layer 30 and the spraying of the curing agent 32 to the first mortar layer 30 to occur in parallel. More specifically, while the nozzle 15 is discharging mortar while moving in the opposite direction (opposite Y arrow direction), the spraying sections 24, 25 move in the same direction and spray the curing agent 32 onto the side surface of the mortar layer 30 below the layer being laminated. The spraying only needs to be done so that the curing agent 32 is evenly sprayed onto the side surface of the mortar layer 30, and the curing agent 32 may be sprayed continuously or intermittently.

[0027] When the movement control unit 43 reaches the end of the second layer's path, it raises the nozzle 15 by a predetermined distance based on the path data, then reverses direction and moves it forward. The discharge control unit 44 continues to discharge mortar from the nozzle 15 to form the third mortar layer 30. The spraying units 24 and 25 spray the curing agent 32 onto the second mortar layer 30 based on the path data.

[0028] In this way, the process of the nozzle 15 forming the Nth layer of mortar 30 and the process of the spraying units 24 and 25 spraying the curing agent 32 onto the side surface of the (N-1)th layer of mortar 30 proceed simultaneously (N=1,2,...Nmax).

[0029] Then, when the nozzle 15 has finished forming the uppermost layer (N=Nmax) of the mortar layer 30, the discharge control unit 44 stops discharging the mortar from the nozzle 15. The movement control unit 43 moves the nozzle 15 and the support member 20 according to the path data. Based on the path data, the spraying control unit 45 sprays the curing agent 32 from the spraying units 24 and 25 onto the sides of the uppermost layer of mortar layer 30. At this time, the spraying units 24 and 25 may also spray the curing agent 32 onto the flat surface of the uppermost layer of mortar layer 30.

[0030] [Operation of this embodiment] In this way, the spraying sections 24 and 25 spray the curing agent 32 in accordance with the movement of the nozzle 15, making it easy to cure even mortar structures with complex shapes. Furthermore, when the manufacturing system 10 forms an embedded formwork that will be used as part of the structure without being removed after placement as a mortar structure, the spraying mechanism 13 sprays the primer onto the mortar layer 30, and the primer functions as a water absorption regulator. This increases the adhesion between the embedded formwork and the concrete placed inside it at the joint.

[0031] [Effects of this embodiment] As described above, the above embodiment provides the following effects. (1) According to the above embodiment, the curing work of mortar structures can be automated. In addition, since wet curing using curing mats is not required, the generation of waste materials (used curing mats, etc.) can be suppressed. Furthermore, since the curing work can be performed while the mortar layers 30 are being laid, the evaporation of moisture from one or more laid mortar layers 30 is prevented, and the quality of the mortar structure is improved. Furthermore, even mortar structures with complex shapes can be cured.

[0032] (2) The spraying mechanism 13 sprays the curing agent 32 onto the side surface of the mortar layer 30 below the layered mortar layer 30. In other words, the curing agent 32 is not sprayed onto the flat surface of the lower mortar layer 30, so the curing agent 32 is less likely to penetrate between the layers. Therefore, it is possible to suppress the reduction in strength caused by the curing agent 32 penetrating between the layers.

[0033] (3) The spraying sections 24 and 25, located on the sides of the nozzle 15, spray the curing agent 32 onto the sides of the mortar layer 30. In other words, since the spraying sections 24 and 25 are located on the support member 20 attached to the nozzle 15, the spraying of the curing agent 32 can proceed simultaneously with the lamination of the mortar layer 30. Furthermore, since the spraying sections 24 and 25 spray the curing agent 32 onto the sides of the mortar layer 30, it is possible to suppress the reduction in strength caused by the curing agent 32 seeping into the interlayers.

[0034] [Example of changes] Each of the above embodiments can be implemented with the following modifications. Each embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0035] In the above embodiment, the spraying mechanism 13 is equipped with spraying sections 24 and 25, but there may be only one spraying section for spraying the curing agent 32. Also, the spraying mechanism 13 may be equipped with three or more spraying sections. For example, there may be two spraying sections 24 that simultaneously spray the curing agent 32 onto one mortar layer 30. The spraying sections 24 and 25 only need to be able to spray the curing agent 32 below the mortar layer 30 being laminated. In the above embodiment, the curing agent 32 was sprayed onto the mortar layer 30 one layer below the mortar layer 30 being laminated, but for example, the curing agent 32 may be sprayed two or more layers below the mortar layer 30 being laminated, or the curing agent 32 may be sprayed onto multiple layers at once.

[0036] The spraying sections 24 and 25 may be moved by a mechanism separate from the nozzle 15's moving mechanism 12. For example, a dedicated moving mechanism for the spraying sections 24 and 25 may be provided. The spraying sections 24 and 25 may be configured to move up and down along the second support members 22 and 23. In this embodiment, the second support members 22 and 23 are provided with guide grooves or rails to guide the spraying sections 24 and 25. The lifting mechanism for moving the spraying sections 24 and 25 up and down includes a motor and a transmission mechanism for transmitting power from the motor. By moving the spraying sections 24 and 25 up and down in this manner, the spraying sections 24 and 25 can spray the curing agent 32 not only on the mortar layer 30 one layer below the mortar layer 30 being laminated, but also on the mortar layer 30 below that at any desired timing. For example, the spraying sections 24 and 25 can spray the curing agent 32 onto a predetermined layer multiple times.

[0037] The second support members 22 and 23 may be configured to be rotatable relative to the first support member 21. More specifically, the second support members 22 and 23 may be configured to be rotatable by a predetermined angle around the connection point with the first support member 21. In this case, the second support members 22 and 23 can be rotated to be positioned upward or to the side in places where they would be in the way, such as in narrow areas of a laminate consisting of at least one mortar layer 30.

[0038] In the above embodiment, the spraying sections 24 and 25 are arranged to face the nozzle 15, but the spraying sections 24 and 25 may be provided so as to be rotatable horizontally around the second support members 22 and 23. In this embodiment, the orientation of the spraying sections 24 and 25 can be changed according to the position of the mortar layer 30 to be sprayed.

[0039] In the above embodiment, the moving mechanism 12 moved the nozzle 15, but the mounting surface on which the mortar layer 30 is placed may be constructed using a conveyor belt or the like, and the mounting surface may be moved relative to the nozzle 15. In the above embodiment, the spraying mechanism 13 sprayed the curing agent 32 onto the mortar layer 30. In addition, the spraying mechanism 13 may spray a liquid other than the curing agent 32. For example, after spraying the curing agent 32, the spraying mechanism 13 may spray a coating agent to form a coating layer.

[0040] Next, the technical concepts that can be understood from the above embodiments and alternative examples are described below. [A] A control program that uses a control unit to control a moving mechanism, a dispensing mechanism and a spraying mechanism, wherein the control unit functions as a means of controlling the moving mechanism and the dispensing mechanism to form a mortar layer, and controlling the spraying mechanism to spray a curing agent onto a mortar layer below the mortar layer in the lamination in parallel with the lamination. [Explanation of symbols]

[0041] 10...Manufacturing system, 11...Discharge mechanism, 12...Movement mechanism, 13...Spraying mechanism, 15...Nozzle, 16...Supply hose, 17...Discharge port, 18...Arm, 20...Support member, 21...First support member, 22,23...Second support member, 24,25...Spraying section, 26,27...Hose, 28,29...Spraying port, 30...Mortar layer, 32...Curing agent, 40...Control device, 41...Control unit, 42...Path memory unit, 43...Movement control unit, 44...Discharge control unit, 45...Spraying control unit.

Claims

1. Layers of mortar, A method for manufacturing a mortar structure, comprising spraying a curing agent onto the laminated mortar in parallel with the lamination process.

2. A method for manufacturing a mortar structure according to claim 1, wherein the curing agent is sprayed onto a mortar layer below the mortar layer being laminated.

3. The mortar is discharged from the nozzle to build up layers of mortar. A method for manufacturing a mortar structure according to claim 1 or 2, wherein the curing agent is sprayed onto the side surface of the mortar layer from a spraying section provided to the side of the nozzle.

4. A dispensing mechanism that dispenses mortar from a nozzle and layers the mortar, A moving mechanism for moving the nozzle, A manufacturing system for mortar structures, comprising a spraying mechanism for spraying a curing agent onto the mortar in parallel with the aforementioned lamination.

Images