Systems and methods for reinforcement during additive manufacturing of discontinuously supported structures

Abstract

An end effector is provided. The end effector includes a frame, a reinforcing structure dispenser that is coupled to the frame and configured to discharge a plurality of elongate strands to form a strand pattern, and matrix dispenser that is coupled to the frame and includes a nozzle to discharge a matrix material on the strand pattern so that the plurality of elongate strands is at least partially embedded in the matrix material to achieve a reinforced bead. The end effector further includes a motor that is coupled to the frame and configured to actuate the reinforcing structure dispenser to rotate relative to the frame to achieve the strand pattern. The end effector includes a controller configured to control at least one of the reinforcing structure dispenser, the matrix material dispenser, or the motor.

Description

SYSTEMS AND METHODS FOR REINFORCEMENT DURING ADDITIVE MANUFACTURING OF DISCONTINUOUSLY SUPPORTED STRUCTURESCROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 511,987, filed July 5, 2023, the disclosure of which is hereby incorporated by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

[0002] Not applicable.TECHNICAL FIELD

[0003] This disclosure is directed to systems and methods for additive manufacturing of infrastructure (i.e., additive construction). More specifically, such systems and methods are directed at additive manufacturing techniques for producing discontinuously supported structures (e.g., structures that are not continuously supported), such as raised slabs, overhangs, mezzanines, balconies, canopies, and other elevated structures, using automated systems, which can be applied in a variety of environments, including for both terrestrial and extraterrestrial construction.BACKGROUND

[0004] Concrete is used as a building material for a wide variety of applications and in a wide variety of environments. However, traditional techniques for building infrastructure with concrete are very labor-intensive, requiring that workers assemble formwork (e.g., a hollow, external structure forming a negative shape of the final structure) into which wet concrete is poured and then cured to take on the desired, final shape. Because the formwork must provide a negative shape of the final structure, use of formwork can limit the types and shapes of structures that can be produced. Furthermore, the use of formwork in traditional construction also adds significant cost, accounting for anywhere between 35% and 65% (e.g., about 40%) of the total cost of construction. Correspondingly, formwork makes customization more expensive.

[0005] One way to alleviate some of the shortcomings associated with traditional concrete construction using formwork is to use additive manufacturing, which three-dimensionally prints a structure, layer by layer, without the need for traditional formwork. For example, concrete can be printed (e.g., deposited via extrusion by an automated extruder) onto a continuous base structure or existing deposited concrete material to gradually build the desired structure. As a result, the structure can be made without having to assemble formwork, leading to reduced production time, cost, and labor requirements, while also giving the ability to produce highly complex and highly customizable structures that would not otherwise be feasible or possible with traditional construction methods.

[0006] These benefits are particularly useful in extraterrestrial construction applications, which can pose hazards far too dangerous for humans to be on site for extended periods of time, or to be on site at all. Further, use of additive construction techniques allows for material to be used in situ, thus, drastically reducing the amount on material that must be transported from earth.

[0007] However, as mentioned above, such known additive construction techniques generally require that each subsequent layer be deposited on a base structure or previously deposited layer, which provide continuous and direct support to the subsequent layer along its entire length. This is particularly important given the highly viscous, yet liquid nature of concrete prior to curing. Consequently, these known additive construction techniques are incapable of building discontinuously supported structures, including, for example, raised roof slabs and overhangs, which must then be added using other processes and techniques (e.g., by securing a pre-formed component to a base structure created using additive construction techniques).

[0008] In light of at least the above, there exists a need for additive construction techniques that can directly produce discontinuously supported structures. Furthermore, it is desirable that such additive construction techniques can be partially or fully automated to minimize the need for manual labor or intervention. The discussion above is merely provided for general background information and is not intended to unduly limit the scope of the claimed subject matter.SUMMARY

[0009] The above problems can be solved by systems and methods for enabling reinforcement during manufacturing a discontinuously supported structure using an automated extruder (e.g., an extrusion system that is controlled by an electronic controller).

[0010] According to one aspect of the disclosure, an end effector is provided. The end effector can include a frame, a reinforcing structure dispenser that is coupled to the frame and configured to discharge a plurality of elongate strands to form a strand pattern, and matrix dispenser that is coupled to the frame and includes a nozzle to discharge a matrix material on the strand pattern so that the plurality of elongate strands is at least partially embedded in the matrix material to achieve a reinforced bead. The end effector can further include a motor that is coupled to the frame and configured to actuate the reinforcing structure dispenser to rotate relative to the frame to achieve the strand pattern. The end effector can include a controller configured to control at least one of the reinforcing structure dispenser, the matrix material dispenser, or the motor.

[0011] In some examples, the end effector can include a primary gear that transmits torque from the motor to rotate the reinforcing structure dispenser.

[0012] In some examples, the end effector can include a rod that pivotally secures the reinforcing structure dispenser to a secondary gear that engages with the primary gear.

[0013] In some examples, the plurality of elongate strands and the matrix material can be concurrently discharged from the reinforcing structure dispenser and the matrix material dispenser, respectively.

[0014] In some examples, the plurality of elongate strands can be arranged so that a first elongate strand that is positioned within a first half of a cross section of a bead of the matrix material that is dispensed from the nozzle and a second elongate strand is positioned within a second half of the cross section of the bead.

[0015] In some examples, the plurality of elongate strands can include a third elongate strand that is positioned within the first half of the cross section of the bead.

[0016] In some examples, the nozzle can include a width that is greater than a diameter of the plurality of elongate strands.

[0017] In some examples, the end effector can include a guide that is configured to receive the plurality of elongate strands to direct a discharge position of the plurality of elongate strands.

[0018] In some examples, the guide can be coupled to a platform that pivotally supports the reinforcing structure dispenser.

[0019] In some examples, the controller can be configured to rotate the reinforcing structure dispenser to deposit the plurality of elongate strands between a first support portion and a second support portion. The first support portion and the second support portion can each include a plurality of anchors that the plurality of elongate strands wrap around form a discontinuously supported structure.

[0020] In some examples, the plurality of elongate strands can include at least one of basalt or poly-paraphenylene terephthalamide (e.g., Kevlar®) strands.

[0021] In some examples, the end effector can include a plurality of tensioners that are configured to control tension of the plurality of elongate strands.

[0022] According to one aspect of the disclosure, a method of manufacturing a discontinuously supported structure is provided. The method can include securing, with an end effector, a plurality of elongate strands to a base structure. The base structure can define a first support portion and a second support portion. The plurality of elongate strands can be secured to each of the first support portion and the second support portion to form a strand pattern between the first support portion and the second support portion. The method can further include extruding, using the end effector, a matrix material onto the plurality of elongate strands to at least partially embed the plurality of elongate strands within the matrix material to form a reinforced bead.

[0023] In some examples, securing the plurality of elongate strands to the base structure can include wrapping a plurality of elongate strands around a first anchor structure provided along the first support portion and a second anchor structure provided along the second support portion.

[0024] In some examples, the first anchor structure can include a first plurality of anchors and a second plurality of anchors that are oriented in a different direction than the first plurality of anchors. The second anchor structure can include a third plurality of anchors and a fourth plurality of anchors that are oriented in a different direction than the third plurality of anchors.

[0025] In some examples, the method can include applying a tension to the plurality of elongate strand with a tensioner to a frame that supports a reinforcing structure dispenser. The reinforcing structure dispenser can be configured to discharge a plurality of elongate strands. The frame can further support a matrix material dispenser that is coupled to the frame and include a nozzle to discharge the matrix material.

[0026] In some examples, the method can include rotating the reinforcing structure dispenser relative to the frame.

[0027] In some examples, rotating the reinforcing structure dispenser relative to the frame can include controlling a motor that is coupled to the frame with an electronic controller.

[0028] In some examples, the method can include guiding the plurality of elongate strands to achieve a predetermined spatial arrangement of the plurality of elongate strands within the matrix material.

[0029] In some examples, at least one strand of the plurality of elongate strands can be fully encapsulated within the matrix material.

[0030] This Summary and the Abstract are provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter.DRAWINGS

[0031] The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the disclosure. Given the benefit of this disclosure, skilled artisans will recognize the examples provided herein have many useful alternatives that fall within the scope of the disclosure.

[0032] FIG. 1 is a perspective view of a base structure, according to aspects of the disclosure.

[0033] FIG. 2 is a perspective view of the base structure of FIG. 1 with an anchor structure, according to aspects of the disclosure.

[0034] FIG. 3 is a perspective view of reinforced beads secured to the base structure with the anchor structure of FIG. 2, according to aspects of the disclosure.

[0035] FIG. 4 is a top plan view of a reinforcing structure secured to a base structure with an anchor structure, according to aspects of the disclosure.

[0036] FIG. 5 is a top plan view of a reinforcing structure secured to a base structure with an anchor structure, according to aspects of the disclosure.

[0037] FIG. 6 is a perspective view of an extruder extruding a matrix material onto a reinforcing structure, according to aspects of the disclosure.

[0038] FIG. 7 is a cross-sectional view of the matrix material and the reinforcing structure of FIG. 6, taken along line 7-7 shown in FIG. 6.

[0039] FIG. 8 is a schematic view of a plurality of reinforced beads and an unreinforced bead, according to aspects of the disclosure.

[0040] FIG. 9 is a perspective view of unreinforced beads supported on a plurality of reinforced beads, according to aspects of the disclosure.

[0041] FIG. 10 is a perspective view of unreinforced beads supported on a plurality of reinforced beads, according to aspects of the disclosure.

[0042] FIG. 11 is a perspective view of an end effector, according to aspects of the disclosure.

[0043] FIG. 12 is a perspective view of a nozzle of the end effector of FIG. 11, showing a first end of the nozzle, according to aspects of the disclosure.

[0044] FIG. 13 is another perspective view of the nozzle of FIG. 12, showing a second end of the nozzle, according to aspects of the disclosure.

[0045] FIG. 14 is a perspective view of reinforcement members in guides of the end effector of FIG. 11, according to aspects of the disclosure.

[0046] FIG. 15 is a plot of stress-strain curves for an example reinforced bead obtained from experimental data.

[0047] FIG. 16 is a plot of a load- defl ection curves for an example reinforced bead obtained from experimental data.

[0048] FIG. 17 is a plot of a force-deflection curves for an example reinforced bead obtained from experimental data.DETAILED DESCRIPTION

[0049] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” and variations thereof, herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,”and “coupled,” and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Likewise, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings unless identified as such. Furthermore, throughout the description, terms such as front, back, side, top, bottom, up, down, upper, lower, inner, outer, above, below, and the like are used to describe the relative arrangement and / or operation of various components of the example embodiment; none of these relative terms are to be construed as limiting the construction or alternative arrangements that are within the scope of the claims.

[0050] Additionally, as used herein, unless otherwise limited or defined, “or” indicates a non-exclusive list of components or operations that can be present in any variety of combinations, rather than an exclusive list of components that can be present only as alternatives to each other. For example, a list of “A, B, or C” indicates options of: A; B; C; A and B; A and C; B and C; and A, B, and C. Correspondingly, the term “or” as used herein is intended to indicate exclusive alternatives only when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” For example, a list of “one of A, B, or C” indicates options of: A, but not B and C; B, but not A and C; and C, but not A and B. A list preceded by “one or more” (and variations thereon) and including “or” to separate listed elements indicates options of one or more of any or all of the listed elements. For example, the phrases “one or more of A, B, or C” and “at least one of A, B, or C” indicate options of: one or more A; one or more B; one or more C; one or more A and one or more B; one or more B and one or more C; one or more A and one or more C; and one or more of A, one or more of B, and one or more of C. Similarly, a list preceded by “a plurality of’ (and variations thereon) and including “or” to separate listed elements indicates options of multiple instances of any or all of the listed elements. For example, the phrases “a plurality of A, B, or C” and “two or more of A, B, or C” indicate options of: A and B; B and C; A and C; and A, B, and C.

[0051] Further, unless otherwise specified or limited, the terms “about” and “approximately” as used herein with respect to a reference value refer to variations from the reference value of ± 5%, inclusive. Similarly, the term “substantially” as used herein with respect to a reference value refers to variations from the reference value of less than ± 30%, inclusive. Unless otherwise noted, ranges as listed herein are inclusive of endpoints of the range.

[0052] The following discussion is presented to enable a person skilled in the art to make and use embodiments of the disclosure. Given the benefit of this disclosure, variousmodifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the principles herein can be applied to other embodiments and applications without departing from embodiments of the disclosure. Thus, embodiments of the disclosure are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the disclosure. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the disclosure.

[0053] As noted above, a need exists for a method for additive manufacturing (i.e., constructing) of discontinuously supported structures, in particular, cementitious structures, without the need for continuous external formwork required by conventional construction and additive manufacturing techniques. For the purpose of this discussion, such discontinuously supported structures (e.g., a slab) include structures that are directly supported along their periphery (e.g., along a peripheral edge), or a portion thereof, by a base structure, and which include an unsupported area (e.g., a central area or span) that is not directly supported by the base structure or another structure engaged with a foundation surface (e.g., ground). Some nonlimiting examples of unsupported structures include raised slabs, such as those used in roofs, mezzanines, ceilings, balconies, canopies, overhangs, etc.

[0054] Such methods for additive manufacturing of unsupported structures can be particularly useful in constructing (e.g., by three-dimensional printing / extruding) slabs and other discontinuously supported structures that are angled to be below a self-supporting angle of the matrix material being used. The self-supporting angle of a matrix material is the angle at which the extruded matrix material can extend (e.g., an angle of the final structure formed by the matrix material), relative to a horizontal plane (e.g., a plane that is perpendicular to a gravitational force). Generally, with conventional additive manufacturing systems, a matrix material cannot be printed at angles that are less than the self-supporting angle of the matrix material (e.g., between approximately 50 degrees and approximately 70 degrees for cementitious materials, depending on material composition and viscosity) without the use of (temporary) external supports that are configured to counter the terrestrial gravitational forces acting on the matrix material. As such, traditional additive manufacturing systems are generally incapable of building structures below the self-supporting angle of the matrix material withoutusing external supports or formwork, each of which increases cost, complexity, and manufacturing times.

[0055] Relatedly, and in particular with cementitious materials, matrix materials used in three-dimensional printing can be significantly weaker in tension than they are in compression; even more so when in a flowable state, such as that during pouring or extrusion. Accordingly, to improve the tensile strength of a matrix material, reinforcing structures, for example, wire mesh or rebar, can be at least partially embedded within the matrix material in its flowable form, after which the matrix material solidifies as it cures. The reinforcing structure thereby provides internal support to the finished structure (e.g., a concrete slab), improving strength in tension. Generally, with conventional methods, to embed the reinforcing structure in the matrix material, the reinforcing structure is placed within a cavity (e.g., a cavity bounded by formwork or another continuous surface, such as the ground) and the matrix material is poured into the cavity to surround the reinforcing structure. The liquid matrix material is then supported by the walls of the cavity until it solidifies.

[0056] Aspects of the present disclosure provide advantages over such conventional systems and techniques by allowing a matrix material to be extruded to form discontinuously supported structures (e.g., slabs) at or below the self-supporting angle of the matrix material, without the need for external or continuous support structures. More specifically, methods of manufacturing a discontinuously supported structure according to the present disclosure utilize a reinforcing structure to support a matrix material that is in a flowable state. For example, a reinforcing structure can be secured to a base structure along at least a portion of a periphery (e.g., a peripheral, supported area) of the reinforcing structure so that the reinforcing structure defines an unsupported area that is not directly supported by the base structure or another structure engaged with a foundation. A flowable matrix material can then be extruded to be substantially coextensive or simultaneously with the reinforcing structure. That is, the matrix material can be extruded (e.g., to form a plurality of parallel beads of the matrix material) into a first layer that substantially covers an entire area of the reinforcing structure (e.g., to substantially cover and extend throughout both the supported area and the unsupported area). Subsequent layers of the matrix material can then be extruded on top of the first layer. Thus, the reinforcing structure supports the matrix material during printing and may also be at least partially embedded into the matrix material. Consequently, the reinforcing structure may be incorporated (e.g., at least partially embedded) into the matrix material to reinforce the finalstructure (e.g., a slab) once the matrix material solidifies (e.g., cures or otherwise hardens into a solid state), increasing strength of the final structure in tension.

[0057] Additionally, such methods for additive manufacturing of discontinuously supported structures according to this disclosure can be performed using one or more automated extruders (i.e., automated extrusion systems) that are configured to (continuously) extrude a bead of a matrix material in one or more layers to three-dimensionally print an unsupported structure. Automated extruders can include, for example, gantry systems, cable- driven systems, robotic arm systems, and swarm printing systems (e.g., cooperative printing systems using multiple extruders to print a single structure). Moreover, in some cases, and as discussed in greater detail below, an automated extruder (e.g., a 6-axis robotic arm) can be configured to manufacture a discontinuously supported structure without the need for human intervention, including placing reinforcing structures, anchoring systems for such reinforcing structures, and extruding a matrix material. Correspondingly, an automated extruder can be configured to operate one or more implements or tools that allow the automated extruder to perform one or more desired tasks. For example, an automated extruder can include an extruding head for extruding a matrix material and a gripping or other multipurpose head / end effector for manipulating objects, such as for securing a reinforcing structure to a base structure. In some non-limiting examples, an extruder can include multiple heads that can be swapped out to perform a particular task. In other non-limiting examples, specialty, purpose- built machines, or robots can be configured to perform all or a subset of tasks of an automated extrusion system. The extruder head may also include a tensioning device or function to tension the cables. This function of tensioning the cables can be done by the same extruder that extrudes the material or by another extruder. So, for example, a single end effector can be used to deposit both a reinforcing structure and a matrix material (simultaneously or sequentially), or a first end effector can deposit a reinforcing structure while a second end effector can deposit a matrix material.

[0058] Further, aspects of the present disclosure provide a tool (i.e., an end effector for an extruder that may be semi- or fully-automated) that permits reinforcement of a discontinuously supported structure while additively manufacturing the discontinuously supported structures. That is, aspects of the disclose allow for a matrix material to be co-extruded with a reinforcing structure. For example, a reinforcing structure (e.g., a cable, wire, rebar, strand, pipe, rope, etc.) can be deposited between portions of a base structure while the end effector (e.g., concurrently) deposits a matrix material to form discontinuously supported structures. Correspondingly, thereinforcing structure can be at least partially embedded into layers of the matrix material and reinforce an overall printed geometry of the discontinuously supported structures, eliminating the need for external formwork. Such end effectors may also be used to first deposit a reinforcement structure, after which matrix material be deposited thereon.

[0059] In some non-limiting examples, an end effector can include a cable dispenser that winds and tensions the cables (e.g., a reinforcing structure), for example, by wrapping the plurality of cables around an anchor structure of the base structure. Thus, the end effector can provide flexibility in printing flat enclosing structures without external supports or formwork. In non-limiting examples, the end effector can be compatible with the automated extruder as discussed above (e.g., without a need to make adjustments to a hardware of the automated extruder).

[0060] Turning to FIGS. 1-3, a discontinuously supported structure 100 (e.g., a structure having at least a portion that is not directed supported) is illustrated according to aspects of this disclosure. The discontinuously supported structure 100 can be deposited (e.g., extruded by an extruder) on a base structure 102 (e.g., a structure formed by additive manufacturing or other construction techniques). The base structure 102 includes a first support portion 104 and a second support portion 106 that is spaced apart from the first support portion 104. Thus, the discontinuously supported structure 100 can span between the first support portion 104 and the second support portion 106. In some examples, a first support portion and a second support portion may be coupled to one another and still define a spaced region therebetween, over which a discontinuously supported structure can be formed. For example, a first support portion and a second support portion can be walls that are adjoined to define a corner, or a first support portion and a second support portion can be sections of a continuous arc.

[0061] As shown in FIGS. 2 and 3, the base structure 102 can include various structures to secure the discontinuously supported structure 100 to the base structure 102. For example, the first support portion 104 can include a first anchor structure 110 (e.g., a first set of one or more anchors) coupled to the first support portion 104. The second support portion 106 can include a second anchor structure 112 (e.g., a second set of one or more anchors) coupled to the second support portion 106. In the illustrated example, the first anchor structure 110 and the second anchor structure 112 are coupled to a top surface of the first support portion 104 and the second support portion 106, respectively. In other examples, anchors can be attached to other surfaces, including horizontal, vertical, or inclined surfaces, in accordance with a particular application. Such surfaces need not be flat. The first anchor structure 110 and the second anchor structure112 can be protrusions or grooves that secure the discontinuously supported structure 100 to the first support portion 104 and the second support portion 106, respectively. In some nonlimiting examples, the discontinuously supported structure 100 can be attached to the first anchor structure 110 and the second anchor structure 112 via welding, adhesives, fasteners, or other methods of joining.

[0062] For example, a reinforcing structure can be extruded or secured to the first anchor structure 110 and the second anchor structure 112, spanning a space between the first support portion 104 and the second support portion 106. A matrix material can be overlayed (e.g., extruded) over the reinforcing structure. In other non-limiting examples, a matrix material and a reinforcing structure can be extruded simultaneously.

[0063] Turning to FIG. 4, a reinforcing structure 400 for a discontinuously supported structure is illustrated according to various aspects of the disclosure. The reinforcing structure 400 can be implemented in the discontinuously supported structure 100 of FIGS. 1-3 or in various other structures. Similar to the discontinuously supported structure 100 described above, the discontinuously supported structure of FIG. 4 can be implemented in similar contexts or engage with similar features to the discontinuously supported structure 100 of FIGS. 1-3. Thus, like names to designate the same or similar components described above will be used where applicable, and discussion of these components above generally applies relative to the examples below. For example, the discontinuously supported structure of FIG. 4 including the reinforcing structure 400 can be supported on a base structure 404 just as the discontinuously supported structure 100 is supported on the base structure 102.

[0064] In some examples, the discontinuously supported structure can include a matrix material with the reinforcing structure 400 at least partially embedded within the matrix material (e.g., to reinforce an overall structural integrity). The reinforcing structure 400 can be set within the matrix material with an end effector, or the matrix material can be extruded with an extruder over the reinforcing structure 400. In some cases, the reinforcing structure 400 and the matrix material can be co-extruded (e.g., simultaneously). In particular, the reinforcing structure 400 can be supported on the base structure 404 that includes a first support portion 406 and a second support portion 408 that is distanced from the first support portion 406. Thus, the reinforcing structure 400 can span across a space between the first support portion 406 and the second support portion 408.

[0065] A first anchor structure 420 can be provided along the first support portion 406, and a second anchor structure 430 can be provided along the second support portion 408, to provideanchor points to secure the reinforcing structure 400 to the base structure 404. In the present embodiment, the first anchor structure 420 includes a first plurality of anchors 422 and a second plurality of anchors 424. The first plurality of anchors 422 can include anchors that generally extend in a direction perpendicular to a length direction of the first support portion 406 (e.g., to perpendicular to a direction along which the reinforcing structure 400 spans between the first support portion 406 and the second support portion 408). That is, the anchors of the first plurality of anchors 422 can be longitudinally oriented toward the second support portion 408. Correspondingly, the reinforcing structure 400 can span across the space between the first support portion 406 and the second support portion 408 in a direction generally parallel to the anchors of the first plurality of anchors 422. The second plurality of anchors 424 can include anchors that generally extend in a direction parallel to a length direction of the first support portion 406. Accordingly, the reinforcing structure 400 can span across the space between the first support portion 406 and the second support portion 408 in a direction generally transverse to anchors of the second plurality of anchors 424.

[0066] Further, the anchors for each of the first plurality of anchors 422 and the second plurality of anchors 424 can optionally have varying dimensions including lengths and heights. In particular, the first plurality of anchors 422 can be arranged in an order of decreasing lengths from an outer side (e.g., left side as shown in FIG. 4) of the first support portion 406. The second plurality of anchors 424 can be arranged in an order of decreasing heights from an outer side (e.g., top side as shown in FIG. 4) of the first support portion 406.

[0067] In some examples, the first plurality of anchors 422 or the second plurality of anchors 424 can each be provided on a plate to be secured (e.g., welded, fastened, etc.) to the first support portion 406. The plate can be rotated or translated relative to the first support portion 406. Thus, it is possible to modify a direction that the first plurality of anchors 422 or the second plurality of anchors 424 extend relative to the first support portion 406. In other examples, anchors with different shapes and arrangements can be used to provide sufficient support in accordance with a particular application. For example, anchors can be provided as pins, hooks, etc. In addition, an anchor can be configured to support one or more segments of a reinforcing structure.

[0068] Continuing, a second anchor structure 430 is provided on the second support portion 408. The second anchor structure 430 can include a first plurality of anchors 432 and a second plurality of anchors 434. The second anchor structure 430 is generally similar to the first anchor structure 420, except the second anchor structure 430 is rotated by approximately 180 degreesrelative to the first anchor structure 420. To that end, like names to designate the same or similar components described above will be used where applicable, and discussion of these components above generally applies relative to the second anchor structure 430 unless otherwise noted.

[0069] In some embodiments, the reinforcing structure 400 can be arranged and configured as a structure comprised of one or more elongate strands (e.g., wires, cables, rebar, pipes, strands, ropes, etc.), which can have a variety of cross-sectional shapes as required by a specific application. In non-limiting examples, the reinforcing structure 400 can be continuous and include materials such as basal or Kevlar® (manufactured by DuPont, poly-paraphenylene terephthalamide), although other types of materials are possible. The material of the reinforcing structure 400 can exhibit a bonding characteristic sufficient to form an adequate amount of bonding with a matrix material (e.g., without slipping off the reinforcing structure 400) when reinforced with the matrix material.

[0070] The reinforcing structure 400 can include a plurality of elongate strands that wrap around one or more of the first plurality of anchors 422, the second plurality of anchors 424, the first plurality of anchors 432, and the second plurality of anchors 434, to form a concentric (rectangular) pattern. For example, an elongate strand may wrap around an anchor of each of the first plurality of anchors 422 (e.g., a first plurality of anchors), the second plurality of anchors 424 (e.g., a second plurality of anchors), the first plurality of anchors 432 (e.g., a third plurality of anchors), and the second plurality of anchors 434 (e.g., a fourth plurality of anchors). Another elongate strand may wrap around a different anchor (e.g., with a different length) of each of the first plurality of anchors 422, the second plurality of anchors 424, the first plurality of anchors 432, and the second plurality of anchors 424. Thus, the strand pattern of the reinforcing structure 400 can include generally rectangular shapes that are concentric. The strand pattern can include other shapes such as a triangle, parallelogram, circle, oval, square, polygon, cross, etc. Relatedly, in other examples, the reinforcing structure can be made of one or more strands, that may be arranged in a closed-shape (e.g., with connected terminal ends,) or an open-shape (e.g., with disconnected terminal ends). For example, a closed shape can be achieved when the terminal ends of a strand are secured to the same anchor, while an open shape can be achieved when the terminal ends of a strand are secured to different anchors. A strand may extend between two, three, four, five, six, or more anchors.

[0071] Referring to FIG. 5, a reinforcing structure 500 for a discontinuously supported structure is illustrated according to various aspects of the disclosure. The reinforcing structure500 has generally similar features as the reinforcing structure 400, with like numerals referring to like features. In some aspects, however, the reinforcing structure 500 and the reinforcing structure 400 differ. For example, the reinforcing structure 500 includes a first anchor structure 520 and a second anchor structure 530 that are arranged differently.

[0072] In particular, the first anchor structure 520 can be provided along a first support portion 506 of a base portion 504 to secure the reinforcing structure 500. The second anchor structure 530 can be provided along a second support portion 508 of the base portion 504 to secure the reinforcing structure 500. The first anchor structure 520 can include a first plurality of anchors 522 and a second plurality of anchors 524 that extend at a non -zero angle (e.g., perpendicularly) relative to the first plurality of anchors 522. The anchors for each of the first plurality of anchors 522 and the second plurality of anchors 524 can have varying dimensions including heights and lengths. For example, the first plurality of anchors 522 can be arranged in an order of increasing lengths from an outer side (e.g., left side as shown in FIG. 5) of the first support portion 506. The second plurality of anchors 524 can be arranged in an order of decreasing lengths from an outer side (e.g., top side as shown in FIG. 4) of the first support portion 506. In some embodiments, the anchors can be positioned in different directions and orientations.

[0073] Continuing, a second anchor structure 530 is provided on the second support portion 508. The second anchor structure 530 can include a first plurality of anchors 532 and a second plurality of anchors 534. The second anchor structure 530 is generally similar to the first anchor structure 520, except the second anchor structure 530 is rotated by approximately 180 degrees relative to the first anchor structure 520. To that end, like names to designate the same or similar components described above will be used where applicable, and discussion of these components above generally applies relative to second anchor structure 530 unless otherwise noted.

[0074] The reinforcing structure 500 can be secured to the first anchor structure 520 and the second anchor structure 530 as the elongate strands wrap around the first plurality of anchors 522, the second plurality of anchors 524, the first plurality of anchors 532, and the second plurality of anchors 534. For example, an elongate strand may wrap around the longest anchor of the first plurality of anchors 522, the shortest anchor of the second plurality of anchors 524, longest anchor of the first plurality of anchors 532, and the shortest anchor of the second plurality of anchors 534. The elongate strand can form a generally rectangular shape, more specifically, a parallelogram. An outermost elongate strand may contact top portions ofthe first plurality of anchors 522 or the first plurality of anchors 532. Thus, one or more elongate strands can be arranged with a greater level of tension, with additional tension or a “tug” experienced at the topmost part of the first plurality of anchors 522 or the first plurality of anchors 532. As will be discussed in greater detail below, this can help supporting a matrix material over the reinforcing structure 500, as the tension can counter an effect of downward force due to gravity and support a weight of the matrix material (e.g., without slack). Thus, it is possible to print discontinuously supported structures without formwork.

[0075] In some non-limiting examples, the elongate strands can be arranged to form a variety of mesh patterns not expressly shown here, including both regular and irregular patterns. Additionally, elongate strands can be sections of a single continuous elongate strand, or they can be separate elongate strand portions. The elongate strands can be overlaid in layers or woven together on site, or the elongate strands can be arranged off-site as a pre-formed mesh that can be attached to a base structure.

[0076] In either case, multiple elongate strands can be secured to one another (e.g., where two elongate strands cross or intersect) to prevent relative movement therebetween and to increase rigidity of the reinforcing structure. Moreover, a pre-determined tension can be applied to the elongate strands to reduce a downward deflection of a reinforcing structure (e.g., to control a vertical displacement of reinforcing structure) once a matrix material is applied to the reinforcing structure, as described in greater detail below. The specific tension applied to the elongate strands can vary depending on the specific application, including for example, the material, number, and size of the elongate strands, and the mass of the matrix material or other load being supported. In some cases, the tension applied to the elongate strands can be selected to limit downward deflection to a maximum amount permitted by a building code or other rule or ordinance.

[0077] FIGS. 6 and 7 illustrate a reinforced bead 600 that includes a matrix material 602 reinforced with a reinforcing structure 604. The matrix material 602 in an extrudable (e.g., flowable) state can be extruded onto the reinforcing structure 604 using an extruder 620 (e.g., mounted on an end effector). In some cases, the extruder 620 can be used to provide the reinforcing structure 604 to be secured a base structure (not shown). In general, the extruder 620 can extrude the matrix material 602 (e.g., in accordance with commands from an electronic control system, see FIG. 11) to be substantially coextensive with the reinforcing structure 604. That is, the extruder 620 can extrude the matrix material 602 to substantially cover and extend throughout the reinforcing structure 604. In this way, the matrix material 602 is supported bythe base structure or the reinforcing structure. In some cases, the reinforced bead 600 can exhibit composite behavior at a non-slip interface between the solidified matrix material 602 and the reinforcing structure 604. Under composite behavior, tensile loading on the structure is distributed through both the solidified matrix material and the reinforcing structure.

[0078] Continuing, the reinforcing structure 604 can be provided with one or more elongate strands. For example, a first elongate strand 606 and a second elongate strand 608 can be positioned on generally an upper half (e.g., a first half) of the reinforced bead 600 (e.g., above a dashed line in FIG. 7). The first elongate strand 606 and the second elongate strand 608 can be positioned on opposite ends of the reinforced bead 600 along a width direction. The first elongate strand 606 and the second elongate strand 608 can help supporting the matrix material 602 during extrusion (e.g., to prevent the matrix material 602 from flowing downward due by gravity), as well as increasing the strength of the discontinuously supported structure once the matrix material 602 has hardened (e.g., dried or cured). Additionally or alternatively, the reinforcing structure 604 can include a third elongate strand 610 positioned on generally a lower half (e.g., a second half) of the reinforced bead 600 (e.g., below the dashed line in FIG. 7). The third elongate strand 610 can provide a greater tensile strength to the matrix material 602, particularly when force is applied from the first elongate strand 606 and the second elongate strand toward the third elongate strand 610.

[0079] In some examples, the extruder 620 can have a varying nozzle size to optimize the shape or configuration of the reinforced bead 600 (e.g., based on desired structural behavior of the reinforced bead 600). For example, a smaller nozzle or a larger nozzle can be provided to extrude less or greater amount of a matrix material, respectively. For example, the nozzle shape or size can be varied to produce a reinforced bead with a varying width (e.g., 1.5 cm). Further, increasing the nozzle size to extrude a greater amount of matrix material can provide an increased volume to include additional elongate strands within the matrix material 602 (e.g., to increase density of reinforcement). Relatedly, while the reinforced bead 600 includes one elongate strand on the bottom half, more elongate strands including two, three, four, five, etc. can be provided. While the illustrated reinforced bead 600 includes three elongate strands, less or more elongate strands including one, two, four, five, etc. can be provided (e.g., on the top half, the bottom half, or a combination of both).

[0080] FIG. 8 illustrates a discontinuously supported structure 800having a plurality of reinforced beads 802 and an unreinforced bead 804 (e.g., formed by a solidified matrix matrix) supported on the plurality of reinforced beads 802. The discontinuously supported structure800can include one or more gaps defined by a gap distance 806 (e.g., a bridging distance) between the plurality of reinforced beads 802. For example, the gap distance 806 can be a maximum distance that the unreinforced bead 804 can span between the plurality of reinforced beads 802 without failure (e.g., breaking, fracturing, excessive drooping) due to factors such as weight of the unreinforced bead 804, curing time, viscosity, self-supporting angle of the matrix material. In some cases, the gap distance 806 is about 8 cm, although a smaller or greater value is possible. In some examples, the gap distance 806 can be determined, at least in part, based on an arrangement of a plurality of anchors on a support portion, as discussed above in relation to FIGS. 4 and 5, as well as tension on the elongate strands. In some implementations, a matrix material of a reinforced bead can (e.g., completely) fill the gaps between the plurality of anchors.

[0081] FIG. 9 illustrates a discontinuously supported structure 900 (e.g., a slab) that includes a plurality of reinforced beads 902 and an unreinforced beads 904 supported on the plurality of reinforced beads 902. The discontinuously supported structure 900 may be supported on a base structure (not shown). A layer of the plurality of reinforced beads 902 can extend in one direction and form a one-way slab. Correspondingly, loads from the unreinforced beads 904 can be transferred to the base structure in the one direction.

[0082] FIG. 10 illustrates a discontinuously supported structure 1000 (e.g., a slab) that includes a plurality of reinforced beads 1002 and an unreinforced beads 1004 supported on the plurality of reinforced beads 1002. Multiple layers of the plurality of reinforced beads 1002 can extend in multiple directions. In the present embodiment, a layer of the plurality of reinforced beads 1002 extends in a direction perpendicular to another layer of the plurality of reinforced beads 1002 (e.g., forming a two-way slab). Correspondingly, loads from the unreinforced beads 1004 can be transferred to the base structure in multiple (e.g., two) directions. In some non-limiting examples, each slab of the two-way slabs can be flat or slanted although each slab need not be flat or slanted and may be non-uniformly shaped. For example, in some cases a formed slab can be curved in one or more directions to have an arcuate, curvilinear, or curviplanar shape.

[0083] Referring to FIG. 11, an end effector 1100 is illustrated according to aspects of the present disclosure. The end effector 1100 can be provided to perform a 3D concrete printing process that implements reinforcement of a matrix material. For example, the matrix material can be extruded via an extruder while a reinforcing structure (e.g., strands) are deposited to be at least partially embedded within the matrix material. In some examples, the reinforcingstructure can include elongate strands that can form a pattern (e.g., a grid or mesh, as generally described above) that the matrix material can be extruded on. The elongate strands and the matrix material can both be deposited by the end effector 1100, enhancing efficiency and productivity of the 3D concrete printing process.

[0084] In the illustrated example, the end effector 1100 can be an assembly of various mechanical or electrical components that can be operated as an addition or attachment for a machine including an automated equipment (e.g., a robotic arm) or a gantry system. The end effector 1100 can include a frame 1102 that can be provide a structural foundation to support the various mechanical or electrical components and secure the end effector 1100 to the equipment. Thus, the frame 1102 can provide stability and support for the end effector 1100 during operation of the machine. In some examples, the frame 1102 can include a board that is wooden or a metal piece (e.g., steel) that can be partially welded to the machine.

[0085] Continuing, the end effector 1100 includes a matrix material dispenser 1110 for dispensing a matrix material. In particular, the matrix material dispenser 1110 can include a supply tube 1112 that can receive the matrix material. The supply tube 1112 can be provided near a top portion of the end effector 1100, although the supply tube 1112 can be provided elsewhere that can provide a flow of the matrix material. Further, a shaft 1114 is provided that can be coupled to a bottom part of the supply tube 1112, and the matrix material can further travel downward through the shaft 1114. In the present embodiment, a nozzle 1120 is provided at an end of the shaft 1114 and discharge the matrix material through. As will be discussed in detail below, the nozzle 1120 can be shaped and sized to permit the matrix material to flow out of the nozzle 1120 in a desired shape or rate. The supply tube 1112, the shaft 1114, and the nozzle 1120 are rigidly coupled to another or fixed relative to the frame 1102 in the present example. In some cases, one or more of the supply tube 1112, the shaft 1114, and the nozzle 1120 may move or rotate relative to one another or the frame 1102 to provide a greater flexibility in operating the matrix material dispenser 1110 (e.g., to orient the nozzle 1120 as desired). For example, the nozzle 1120 can rotate relative to the supply tube 1112 in some configurations.

[0086] Continuing, the reinforcing structure dispenser 1140 is provided to deposit elongate strands to reinforce the matrix material. In particular, the reinforcing structure dispenser 1140 can rotate relative to the frame 1102 to wind or control tension of the elongate strands (e.g., around a plurality of anchors) as they become discharged (e.g., to form a strand pattern). In some cases, the reinforcing structure dispenser 1140 can rotate freely, or can be actively rotatedby a drive system. For example, the end effector 1100 can include a motor 1160 that transmits torque to spin a primary gear 1162. A secondary gear 1164 (e.g., a pinion gear) can be provided and rotate in a direction opposite of the primary gear 1162 as teeth of the secondary gear 1164 mesh with teeth of the primary gear 1162. The secondary gear 1164 is concentric or parallel with a first bearing 1166 that engages with the shaft 1114 or the supply tube 1112. Thus, as the secondary gear 1164 rotates, the matrix material dispenser 1110 can remain stationary, and the reinforcing structure dispenser 1140 can rotate relative to the frame 1102. In other example, other types of drive systems, for example, belt drives, rack and pinion systems, linear or rotational actuators, etc. can be used to control rotation of the reinforcing structure dispenser 1140.

[0087] In some examples, a platform 1170 can be provided at a bottom portion of the end effector 1100 to support the reinforcing structure dispenser 1140. The end effector 1100 can include one or more connecting rods 1172 that extend through the reinforcing structure dispenser 1140 and be secured (e.g., fastened) to the platform 1170 and the secondary gear 1164 at a respective opposing distal end of the connecting rod 1172. Thus, as the secondary gear 1164 rotates as initiated by the motor 1160, the platform 1170 and the reinforcing structure dispenser 1140 can rotate with the secondary gear 1164.

[0088] With continued reference to FIG. 11, the reinforcing structure dispenser 1140 can include one or more feeders 1142 that can each support an elongate strand and aid in controlling tension applied to the elongate strand. In particular, the one or more feeders 1142 can be arranged on the one or more connecting rods 1172 to achieve a desired configuration for the strand pattern or provide a desired tension of the elongate strands. The feeder 1142 can be secure to the frame 1102 or the reinforcing structure dispenser 1140 In the illustrated example, the feeder 1142 can include a support 1144 that is pivotally or fixedly secured to the connecting rod 1172 (e.g., to extend radially outward). Further, a second bearing 1168 can be provided and positioned concentrically with the platform 1170, such that the platform 1170 can rotate relative to the frame 1102 or otherwise fixed parts such as the shaft 1114. In some examples, an orientation of the support 1144 can be adjusted (e.g., rotated about the connecting rod 1172) to accommodate footprint of the end effector 1100 as desired or control tension of the elongate strands further.

[0089] In the present example, the feeder 1142 includes an idler 1146 that can be configured to receive an elongate strand wound (e.g., wrapped) around the idler 1146. In some cases, the elongate strand can be in a spool that is supported on the idler 1146, or a spool ofelongate strand can be supported on another structure, for example, the frame 1102. The feeder 1142 can further include a tensioner 1148 (e.g., a clutch) at a distal end of the idler 1146. The tensioner 1148 can include various mechanical parts (e.g., a spring, a nut, etc.) that can provide a level of tension to the elongate strand as it becomes unwound from the idler 1146. In some cases, the tensioner 1148 can be a passive tensioner that allows the elongate strand to be dispenser at predetermined tension or range of tensions. In some variations, a variable tension controlling system (e.g., hysteresis brake system) can be provided to ensure consistent tension on the cables and mitigate unwanted tensioned caused by friction between the cable and the reinforcing structure dispenser 1140. In other examples, the tensioner 1148 can be an active tensioner (e.g., an electronic clutch) that can be controlled (e.g., via an electronic controller) to modulate tension on the elongate strand as it is being dispensed.

[0090] In some examples, with a specific reference to FIG. 14, the elongate strand can be threaded through a guide 1180 (e.g., a tube or channel) that can queue the elongate strand to be deposited (e.g., by straightening out) or direct deposition of the elongate strand. In this way, the guide 1180 can also control the relative space of elongate strands as they are being laid. Accordingly, as the secondary gear 1164 propels movement of the reinforcing structure dispenser 1140, elongate strands can be unwound from the feeder 1142 to provide the elongate strands with desired tension or discharged through the guides 1180 to achieve a desired strand pattern. Thus, controlled movement and positioning of the end effector 1100 can be possible, enabling cable laying maneuvers (e.g., between pluralities of anchors on a support structure or desired locations as described above) at a greater degree of precision, accuracy, and reliability while operating with the matrix material dispenser 1110.

[0091] In the present example, three guides 1180 are provided to support three elongate strands. However, in other examples, fewer or more guides (e.g., one, two, four, five, six, etc.) can be provided to support fewer or more elongate strands (e.g., one, two, four, five, six, etc.). Additionally or alternatively, guides need not be positioned linearly or next to one another.

[0092] In some cases, the motor 1160 can be a stepper motor that can operate in a driving mode (e.g., a full-step, a half-step, or a micro-drive, etc.). The driving mode can be adjusted to achieve a desired response including a torque output or a smoothness of the rotation of the reinforcing structure dispenser 1140. For example, a driving mode of the motor 1160 can be adjusted from full-step to half-step to increase a torque output (e.g., by 10%) or enable the motor 1160 to overcome a resistance caused by a strand (e.g., cable) friction, or achieve asmoother rotation of the strand depositing process via a more granular movement of the primary gear 1162 or the secondary gear 1164.

[0093] Continuing, the end effector 1100 can be provided with a controller 1184 that includes various hardware or software components (e.g., a microcontroller, onboard memory, power electronics, etc.) to govern or monitor the cable laying process, including operating the reinforcing structure dispenser 1140. For example, the controller 1184 can command a speed of the motor 1160 when forming a strand pattern (e.g., to adjust tensioning level of a reinforcing structure).

[0094] In some cases, the controller 1184 can manage a coordination between the robotic arm, the end effector 1100, and the 3D Concrete Printing system to ensure a synchronized and optimized operation. For example, the end effector 1100 can be programmed and connected to a robotic arm controller. In some examples, the controller 1184 can include an Input / Output unit that can receive transmitted signals (e.g., 24- V) from the robotic arm controller. The received signals can be converted to a signal (e.g., 5-V) that is compatible with a microcontroller of the controller 1184. The controller 1184 can process the converted signal based on programmed codes, and the processed signals can be sent to a driver of the motor 1160 to initiate an actuation of the end effector 1100.

[0095] FIGS. 12 and 13 illustrate an example nozzle 1200 for a matrix material dispenser, according to an example of the disclosed technology, which can be implemented in place of the nozzle 1120 of FIG. 11 or on various other end effectors. The nozzle 1200 refers to various components of FIG. 11 for brevity, but the nozzle 1200 can be implemented in other end effectors or matrix material dispensers.

[0096] In particular, the nozzle 1200 can aid in providing an adequate flow of extruded matrix material from the supply tube 1112 and the shaft 1114. In the present embodiment, the nozzle 1200 includes a connector 1202 that can be secured to a distal end of the shaft 1114. In particular, the connector 1202 can be shaped to correspond with an outer portion of the shaft 1114, and the connector 1202 can fit over a bottom end of the shaft 1114. The nozzle 1200 includes an outlet 1204 that permits discharge of a matrix material from the nozzle 1200. In the illustrated example, the outlet 1204 is generally rectangularly shaped, although other shapes (e.g., circle, square, polygon, triangle, oval, trapezoid, etc.) are possible.

[0097] Further, depending on a size (e.g., a diameter) of the elongate strand, the nozzle 1200 size can vary to accommodate the size of the elongate strand to allow the elongate strand to at least partially be embedded in the matrix material. For example, an elongate strand of afirst material can have a different diameter than another elongate strand of a second material. For example, an elongate strand made with Kevlar® can have a smaller diameter than an elongate strand made with basalt. Further, a width of the outlet 1204 is approximately the same as a diameter of the connector 1202 in the present embodiment. But a width of the nozzle 1200 can be increased or decreased to extrude a matrix material with a desired dimension to facilitate a proper encapsulation of the elongate strands in the matrix material. For example, a reinforcing material with three elongate strands may require a matrix material extruded with a smaller width or height than a reinforcing material with ten elongate strands.

[0098] Referring to FIG. 14, a bottom portion of the end effector 1100 is illustrated with the guides 1180 supported on a support plate 1182. In the present example, the support plate 1182 is secured to a bottom surface of the platform 1170 and extends downwardly in a direction generally parallel to the guides 1180. The guides 1180 can be secured to the support plate 1182 by a variety of methods of joining (e.g., adhesives, welds, fasteners, cable ties, etc.). Correspondingly, the guides 1180 can be fixedly arranged on the support plate 1182, and the guides 1180 can be fortified by incorporating the support plate 1182 to the end effector 1100. Thus, deposit locations of the elongate strands 1190 can be more reliable and enhance functionality of the reinforcing structure dispenser 1140.

[0099] Experimental Results

[0100] As discussed above, structural behaviors (e.g., tensile strength, friction, failure response, bending response, shear capacity, etc.) of a reinforced bead can depend on the material properties of the reinforcing structure or a matrix material, as well as other operation parameters of an end effector (e.g., a length of an elongate strand embedded in an extruded matrix material, curing time, extrusion speed of a matrix material, etc.). Experiments were carried out to determine example structural behaviors of a reinforced bead.

[0101] The discussion below summarizes properties measurements of the example reinforced bead with a reinforced structure at least partially embedded in a matrix material. The main property characterizations include tensile strength and deflection. The influence of a material type of a reinforcing structure on tensile strength, a length of a reinforcing structure embedded in a matrix material on shear stress, a curing period of a reinforced bead on a failure type were investigated. Notably, the following tests, measurements, and data represent example embodiments and, given the benefit of this disclosure, one of ordinary skill in the art will appreciate the variations and adaptations available that are consistent with the teachings herein.

[0102] FIG. 15 illustrates a stress-strain behavior of a strand based on a material type (e.g., Kevlar® or basalt) of reinforcing structure at least partially embedded in the reinforced bead. In this experiment, Sample 1 was a 20 cm strand including a first material type of a reinforcing structure (Kevlar®), and Sample 2 was a 20 cm strand including a second material type of a reinforcing structure (basalt). Sample 1 and Sample 2 were subject to a gradually increasing tensile force at a rate of 2 kg / s until rupture.

[0103] As shown in FIG. 15, the results revealed that Sample 1 (Kevlar®) demonstrated a tensile strength of up to 2921 MPa, whereas Sample 2 (basalt) exhibited a substantially lower tensile strength, reaching only 947 MPa. The stress-strain behavior of Sample 1 displayed a linear pattern leading to ultimate strength without any indication of strain hardening. Failures primarily occurred near the attachment points, suggesting weakened areas likely due to cable knotting. In contrast, the stress-strain behavior of Sample 2 showed significant deformation, characterized by a distinct pattern where woven fibers failed in three sequential clusters. The initial slope appeared lower than the modulus of elasticity due to cable tightening within the grip. Basalt cables are composed of three wire clusters twisted together within the cable structure. During testing, each of these clusters failed consecutively, resulting in three distinct peaks in the stress-strain curve. Notably, failures tended to concentrate near the hooks, indicating that the rod knotting around these points may have compromised their strength. The modulus of elasticity for Kevlar® was measured at 8.94 GPa, slightly higher than the 8.78 GPa observed for basalt until initial failure occurred. Therefore, a material type of a reinforcing structure can influence tensile strength and behavior of a reinforced bead.

[0104] FIG. 16 illustrates a Load-deflection diagram of a pullout test. This test was performed to evaluate effects of a development length (i.e., a length of a reinforcing material to transfer stresses between the reinforcing material and a matrix material) on friction (e.g., as indicated by shear stress) between the reinforcing material and the matrix material. In this experiment, a reinforcing material (Kevlar®) was embedded into a matrix material of specimens of different development lengths (e.g., 5 cm, 10 cm, or 15 cm, etc.). In particular, Sample 1, Sample 2, and Sample 3 included the reinforcing material with the same material type (e.g., Kevlar®). The reinforcing material was subject to tension loads to reduce or prevent deviation or displacement of the reinforcing material within the matrix material. After being cured for about 7 days, the pullout test was conducted on the specimens.

[0105] As shown in FIG. 16, a load of about 61.6 kgf was applied to Sample 1 (with the length of 10 cm), which exhibited a shear stress of about 0.49 MPa. A load of about 76.7 kgfwas applied to Sample 2 (with the length of 15 cm), which exhibited a shear stress of about 0.42 MPa. A load of about 26.8 kgf was applied to Sample 3 (with the length of 5 cm), which exhibited a shear stress of about 0.40 MPa. Therefore, different lengths of the reinforced beads can exhibit different shear stress behaviors including shear stress capacity.

[0106] FIG. 17 illustrates a force-deflection behavior of a reinforced bead under bending stress. In particular, a 4-point bending test was conducted on samples to evaluate effectiveness of various levels of reinforcement (e.g., no reinforcing material embedded in a matrix material, extruding a matrix material with optimized extrusion parameters, extruding a matrix material through a nozzle to enhance reinforcement, etc.). As shown in FIG. 17, Sample 1 exhibited a brittle fracture response. Sample 2 and Sample 3 exhibited a ductile fracture response. Sample 3 withstood the highest amount of load, indicating the highest maximum load capacity among the specimens and a strong bond between the reinforcing material and the matrix material.

[0107] In some implementations, devices or systems disclosed herein can be utilized, manufactured, installed, etc. using methods embodying aspects of the invention. Correspondingly, any description herein of particular features, capabilities, or intended purposes of a device or system is generally intended to include disclosure of a method of using such devices for the intended purposes, of a method of otherwise implementing such capabilities, of a method of manufacturing relevant components of such a device or system (or the device or system as a whole), and of a method of installing disclosed (or otherwise known) components to support such purposes or capabilities. Similarly, unless otherwise indicated or limited, discussion herein of any method of manufacturing or using for a particular device or system, including installing the device or system, is intended to inherently include disclosure, as embodiments of the invention, of the utilized features and implemented capabilities of such device or system.

[0108] In some non-limiting examples, aspects of the invention, including computerized implementations of methods according to the invention, can be implemented as a system, method, apparatus, or article of manufacture using standard programming or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a processor device (e.g., a serial or parallel general purpose or specialized processor chip, a single- or multi-core chip, a microprocessor, a field programmable gate array, any variety of combinations of a control unit, arithmetic logic unit, and processor register, and so on), a computer (e.g., a processor device operatively coupled to a memory), or another electronically operated controller to implement aspects detailed herein. Accordingly, for example, non-limiting examples of the invention can be implemented as a set of instructions, tangibly embodied on a non-transitory computer-readable media, such that a processor device can implement the instructions based upon reading the instructions from the computer-readable media. Some non-limiting examples of the invention can include (or utilize) a control device such as an automation device, a special purpose or general purpose computer including various computer hardware, software, firmware, and so on, consistent with the discussion herein. As specific examples, a control device can include a processor, a microcontroller, a field- programmable gate array, a programmable logic controller, logic gates etc., and other typical components that are known in the art for implementation of appropriate functionality (e.g., memory, communication systems, power sources, user interfaces and other inputs, etc.). In some non-limiting examples, a control device can include a centralized hub controller that receives, processes and (re)transmits control signals and other data to and from other distributed control devices (e.g., an engine controller, an implement controller, a drive controller, etc.), including as part of a hub-and-spoke architecture or otherwise.

[0109] The term “article of manufacture” as used herein is intended to encompass a computer program accessible from any computer-readable device, carrier (e.g., non-transitory signals), or media (e.g., non-transitory media). For example, computer-readable media can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips, and so on), optical disks (e.g., compact disk (CD), digital versatile disk (DVD), and so on), smart cards, and flash memory devices (e.g., card, stick, and so on). Additionally, it should be appreciated that a carrier wave can be employed to carry computer-readable electronic data such as those used in transmitting and receiving electronic mail or in accessing a network such as the Internet or a local area network (LAN). Those skilled in the art will recognize that many modifications may be made to these configurations without departing from the scope or spirit of the claimed subject matter.

[0110] Certain operations of methods according to the invention, or of systems executing those methods, may be represented schematically in the FIGS, or otherwise discussed herein. Unless otherwise specified or limited, representation in the FIGS, of particular operations in particular spatial order may not necessarily require those operations to be executed in a particular sequence corresponding to the particular spatial order. Correspondingly, certain operations represented in the FIGS., or otherwise disclosed herein, can be executed in different orders than are expressly illustrated or described, as appropriate for particular non-limiting examples of the invention. Further, in some non-limiting examples, certain operations can beexecuted in parallel, including by dedicated parallel processing devices, or separate computing devices configured to interoperate as part of a large system.

[0111] As used herein in the context of computer implementation, unless otherwise specified or limited, the terms “component,” “system,” “module,” “block,” and the like are intended to encompass part or all of computer-related systems that include hardware, software, a combination of hardware and software, or software in execution. For example, a component may be, but is not limited to being, a processor device, a process being executed (or executable) by a processor device, an object, an executable, a thread of execution, a computer program, or a computer. By way of illustration, both an application running on a computer and the computer can be a component. One or more components (or system, module, and so on) may reside within a process or thread of execution, may be localized on one computer, may be distributed between two or more computers or other processor devices, or may be included within another component (or system, module, and so on).

Claims

CLAIMSI / we claim:

1. An end effector comprising: a frame; a reinforcing structure dispenser that is coupled to the frame and configured to discharge a plurality of elongate strands to form a strand pattern; a matrix material dispenser that is coupled to the frame and includes a nozzle to discharge a matrix material on the strand pattern so that the plurality of elongate strands is at least partially embedded in the matrix material to achieve a reinforced bead; a motor that is coupled to the frame and configured to actuate the reinforcing structure dispenser to rotate relative to the frame to achieve the strand pattern; and a controller that is configured to control at least one of the reinforcing structure dispenser, the matrix material dispenser, or the motor.

2. The end effector of claim 1 further comprising a primary gear that transmits torque from the motor to rotate the reinforcing structure dispenser.

3. The end effector of claim 2 further comprising a rod that pivotally secures the reinforcing structure dispenser to a secondary gear that engages with the primary gear.

4. The end effector of claim 1, wherein the plurality of elongate strands and the matrix material are concurrently discharged from the reinforcing structure dispenser and the matrix material dispenser, respectively.

5. The end effector of claim 4, wherein the plurality of elongate strands are arranged so that a first elongate strand is positioned within a first half of a cross section of a bead of the matrix material that is dispensed from the nozzle and a second elongate strand is positioned within a second half of the cross section of the bead.

6. The end effector of claim 5, wherein the plurality of elongate strands further includes a third elongate strand that is positioned within the first half of the cross section of the bead.

7. The end effector of claim 1, wherein the nozzle includes a width that is greater than a diameter of the plurality of elongate strands.

8. The end effector of claim 1 further comprising a guide that is configured to receive the plurality of elongate strands to direct a discharge position of the plurality of elongate strands.

9. The end effector of claim 8, wherein the guide is coupled to a platform that pivotally supports the reinforcing structure dispenser.

10. The end effector of claim 1, wherein the controller is configured to rotate the reinforcing structure dispenser to deposit the plurality of elongate strands between a first support portion and a second support portion that each include a plurality of anchors that the plurality of elongate strands wrap around form a discontinuously supported structure.

11. The end effector of claim 1, wherein the plurality of elongate strands includes at least one of basalt or poly-paraphenylene terephthalamide strands.

12. The end effector of claim 1 further comprising a plurality of tensioners that are configured to control tension of the plurality of elongate strands.

13. A method of manufacturing a discontinuously supported structure, the method comprising: securing, with an end effector, a plurality of elongate strands to a base structure, the base structure defining a first support portion and a second support portion, the plurality of elongate strands being secured to each of the first support portion and the second support portion to form a strand pattern between the first support portion and the second support portion; and extruding, using the end effector, a matrix material onto the plurality of elongate strands to at least partially embed the plurality of elongate strands within the matrix material to form a reinforced bead.

14. The method of claim 13, wherein securing the plurality of elongate strands to the base structure includes wrapping a plurality of elongate strands around a first anchor structure provided along the first support portion and a second anchor structure provided along the second support portion.

15. The method of claim 14, wherein the first anchor structure includes a first plurality of anchors and a second plurality of anchors that are oriented in a different direction than the first plurality of anchors; and wherein the second anchor structure includes a third plurality of anchors and a fourth plurality of anchors that are oriented in a different direction than the third plurality of anchors.

16. The method of claim 13 further comprising applying a tension to the plurality of elongate strand with a tensioner to a frame that supports a reinforcing structure dispenser that is configured to discharge a plurality of elongate strands and a matrix material dispenser that is coupled to the frame and includes a nozzle to discharge the matrix material.

17. The method of claim 16, further comprising rotating the reinforcing structure dispenser relative to the frame.

18. The method of claim 17, wherein rotating the reinforcing structure dispenser relative to the frame includes controlling a motor that is coupled to the frame with an electronic controller.

19. The method of claim 13, further comprising guiding the plurality of elongate strands to achieve a predetermined spatial arrangement of the plurality of elongate strands within the matrix material.

20. The method of claim 13, wherein at least one strand of the plurality of elongate strands is fully encapsulated within the matrix material.

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