Heatable formwork element and formwork system for concreting building parts

Abstract

The invention relates to a heatable formwork element for concreting building parts, comprising the following components: a formwork panel having a formwork shell, a heating element, a panel core and at least one temperature sensor, wherein a surface of the formwork shell forms a workpiece side of the formwork panel which comes into contact with concrete when the heatable formwork element is used as intended, wherein the heating element, in particular a heating fleece, heating wire or heating tube, is arranged between the panel core and the workpiece side and is designed to heat the formwork shell, wherein the panel core receives and / or supports a mechanical load which acts on the heatable formwork element, wherein the at least one temperature sensor is designed to measure a temperature on the workpiece side; and a control device which can be connected or is connected to the temperature sensor for signal transmission and has a switching controller for the heating element, wherein the control device is designed to control a heating power of the heating element depending on a temperature measured by the temperature sensor, and wherein the control device is arranged, in particular attached, on the formwork panel or another component of the formwork element on a side of the formwork element facing away from the formwork shell. The invention further relates to an associated formwork system and to a method for controlling a concrete temperature during concreting of building parts by means of a heatable formwork element or by means of a formwork system.

Description

Heated formwork element and formwork system for concreting OF BUILDING COMPONENTS

[0001] The invention relates to a heated formwork element for concreting structural components, comprising a formwork panel with a formwork skin, a heating element, a panel core, and at least one temperature sensor, as well as a control unit which is connectable to or capable of transmitting signals to the temperature sensor and includes a switching regulator for the heating element. The control unit is configured to regulate the heating power of the heating element as a function of a temperature measured by the temperature sensor, and the control unit is arranged, in particular mounted, on the formwork panel or another component of the formwork element on a side of the formwork element facing away from the formwork skin. Furthermore, the invention relates to an associated formwork system and a method for regulating the concrete temperature during the concreting of structural components using a heated formwork element or a formwork system.

[0002] Formwork is typically used to cast concrete components. This formwork creates a negative mold of the component's shape, into which liquid or cast-in-place concrete is poured. Once the concrete has hardened, the formwork is removed. The service life of formwork materials on the construction site and the associated costs depend on the concrete's curing time. Therefore, it is crucial to closely monitor and, if necessary, influence the concrete's curing time.

[0003] To reduce carbon emissions in the construction industry, there is an increasing use of concrete with a reduced CO2 footprint. However, such concretes generally have the disadvantage of requiring significantly longer curing times, which delays formwork removal. Consequently, the formwork material is used for a longer period, increasing construction time and resulting in higher costs. Furthermore, the minimum temperature required for proper curing and strength development of such concrete is considerably higher than that of conventional concrete.

[0004] To reduce the curing time of concrete, or even to make it possible at low ambient temperatures, heated formwork can be used. Such formwork is supplied with energy that is drawn from the heat emitted by the formwork. The formwork is used to transfer the poured and hardening concrete, thus leading to its heating and acceleration of the hardening process.

[0005] Document CN 105201201 A relates to an intelligent, temperature-controlled, electrically heated formwork element comprising a formwork body with a support plate and a panel, wherein heating wires are located between the support plate and the panel; and an electrical control device comprising an electrical controller and a temperature sensor, wherein the electrical controller is connected to the heating wires or the temperature sensor, the temperature sensor is embedded in the concrete, and the electrical controller serves to detect the signals from the temperature sensor and to switch the heat-generating wires on and off according to the detected signals from the temperature sensor.

[0006] Document DE 20 2021 104 298 U1 relates to a heating and thermal insulation system for a casting formwork during construction in winter, characterized in that it comprises: a heating layer arranged on the outside of the formwork and having a plurality of heating wires; a temperature sensor arranged on the outside of the formwork; a thermal insulation layer applied to the heating layer; and a temperature control system electrically connected to the heating layer and the temperature sensor and designed to control the heating and thermal insulation system.

[0007] It is an object of the invention to provide an improved heated formwork element and an associated formwork system for concreting structural components. In particular, it is an object of the invention to provide a heated formwork element and associated formwork system with which the formwork system can be flexibly adapted to the structure to be built and the effort required for connecting the formwork elements of the formwork system can be minimized.

[0008] This problem is solved by the doctrine of independent claims. Advantageous embodiments are claimed in dependent claims.

[0009] A first aspect of the invention relates to a heated formwork element for concreting structural components, comprising the following components: a formwork panel with a formwork skin, a heating element, a panel core, and at least one temperature sensor, wherein a surface of the formwork skin forms a workpiece side of the formwork panel against which concrete rests during intended use of the heated formwork element, wherein the heating element, in particular a heating fleece, heating wire, or heating tube, is located between the formwork core and the workpiece side and is configured to heat the formwork skin, wherein the formwork core absorbs and / or supports a mechanical load acting on the heatable formwork element, wherein the at least one temperature sensor is configured to measure a temperature on the workpiece side; and a control unit which is connectable to or has a switching regulator for the heating element, wherein the control unit is configured to regulate a heating power of the heating element as a function of a temperature measured by the temperature sensor, and wherein the control unit is arranged, in particular attached, on a side of the formwork element facing away from the formwork skin on the formwork panel or another component of the formwork element.

[0010] A second aspect of the invention relates to a formwork system comprising: a plurality of, in particular 24, heated formwork elements according to the first aspect of the invention; and an energy distributor which is configured to supply the control units of the heated formwork elements with energy, in particular electrical energy or thermal energy, wherein the heated formwork elements and the energy distributor are connectable or connected by means of energy and data transmission connections, in particular electrical cables or hoses, for energy and data transmission.

[0011] A third aspect of the invention relates to a method for controlling a concrete temperature during the concreting of structural components by means of a heated formwork element according to the first aspect of the invention or by means of a formwork system according to the second aspect of the invention, comprising the following steps: measuring a temperature on the workpiece side by means of the temperature sensor; and controlling a heating power of the heating element as a function of a temperature measured by the temperature sensor.

[0012] A formwork skin according to the invention is preferably the outer layer of a formwork panel which, during the intended use of a formwork element, comes into contact with the concrete, particularly via the release agent located between the formwork skin and the concrete, and thus significantly determines the surface of the concrete. A formwork skin according to the invention also preferably serves as a wear layer.

[0013] A heating element according to the invention is preferably configured to convert a form of energy, in particular electrical energy, into thermal energy and to heat an adjacent room or building component using this thermal energy.

[0014] A control unit according to the invention is preferably configured to compare a physical input parameter, in particular a temperature, measured by means of a sensor with a setpoint stored or calculated in the control unit, and in the event of a discrepancy between the measured parameter and the stored value, to adjust a physical process by means of a switching regulator so that the measured actual value matches the setpoint.

[0015] A temperature sensor according to the invention is preferably configured to measure a temperature-dependent electrical signal and to output the temperature prevailing in the vicinity of the temperature sensor on the basis of this electrical signal.

[0016] The invention is based in particular on the approach that all components of the heated formwork element, including the heating element, temperature sensor, and control unit with switching regulator, are arranged or attached directly to, or even integrated into, the heated formwork element, so that all components of the heated formwork element form an independent unit. This makes it possible to optimally control the curing process of the concrete, in particular the curing time of the concrete, individually and according to the conditions prevailing at the respective heated formwork element, and thus to synchronize the stripping time economically.

[0017] Preferably, the signal connection between the control unit and the temperature sensor is wireless. This eliminates the need for a connecting cable between the control unit and the temperature sensor for signal transmission, thus reducing the complexity of the formwork element.

[0018] Preferably, the heating element extends at least substantially over the entire formwork panel. This ensures that the concrete is heated at least substantially uniformly across the entire surface of the heated formwork element and thus hardens uniformly.

[0019] Preferably, the control unit is configured to continuously or quasi-continuously regulate the heating power of the heating element as a function of a temperature measured by the temperature sensor. In particular, the heating power of the heating element can be continuously or quasi-continuously reduced if a temperature measured by the temperature sensor is exceeded. The heating element's output can be continuously or quasi-continuously increased when the temperature measured by the temperature sensor exceeds a setpoint temperature, and when the temperature measured by the temperature sensor falls below a setpoint temperature. Continuous or quasi-continuous control of the heating element's output prevents the heating element from having to be switched on and off within relatively short periods due to fluctuations in the outside temperature, which could negatively affect the quality of the hardened concrete.

[0020] Preferably, the switching regulator of the control unit is a P-controller with proportional behavior, an I-controller with integral behavior, a PI-controller with proportional and integral behavior, a PD-controller with proportional and differential behavior, or a PID-controller with proportional, integral, and differential behavior. A proportional (P) controller is characterized by its simple structure and high robustness. It reacts immediately to a control deviation by adjusting the manipulated variable proportionally. This allows it to respond quickly to changes in the process. The P controller is particularly advantageous for sluggish processes with large delays or dead times, as it often delivers sufficiently good results in these situations. However, a pure P controller always retains a residual control deviation in steady state, which is not completely eliminated. An integral controller (I-controller) has the advantage that it adjusts the manipulated variable by integrating the control deviation until the deviation is completely compensated. This eliminates persistent control deviations and ensures that the setpoint is reached precisely. This makes it particularly suitable for compensating for steady-state disturbances or continuous load changes. However, it reacts more slowly and, if set too aggressively, can lead to oscillations or instabilities. The PI controller combines the characteristics of a P and an I controller, thus uniting fast response time with high control accuracy. While the proportional component ensures rapid response to control deviations, the integral component completely eliminates any remaining deviations. This makes the PI controller suitable for a wide range of industrial applications, where it is frequently used as a standard solution. Furthermore, it offers good disturbance suppression, especially during slow load changes. A proportional-determined (PD) controller, which includes both proportional and differential components, primarily improves the dynamic behavior of the control loop. The differential component acts predictively and compensates for fluctuations in the control loop. Rapid changes are achieved, thereby reducing overshoot and making the system faster overall. This is particularly advantageous in highly dynamic processes or when it is necessary to compensate for delays in the system. However, a PD controller does not eliminate the permanent control error, which is why it is often only used on its own in specific applications. The PID controller ultimately combines all three operating principles: It uses the proportional (P) component for an immediate response, the integral (I) component to completely eliminate persistent control deviations, and the derivative (D) component to reduce overshoot and improve transient response. Thus, the PID controller offers an optimal compromise between fast response time, high accuracy, and good damping, and can be flexibly adapted to a wide variety of processes.

[0021] In an advantageous embodiment of the heated formwork element, the temperature sensor is arranged at least partially between the workpiece side and a rear side of the formwork panel.

[0022] According to the invention, the reverse side of the formwork panel refers to the side of the formwork panel opposite the workpiece side.

[0023] The arrangement of the temperature sensor at least partially between the workpiece side and the back of the formwork panel makes it possible, on the one hand, to measure the temperature of the concrete on the workpiece side, while on the other hand the temperature sensor does not protrude into the concrete.

[0024] In a further advantageous embodiment of the heated formwork element, the core of the plate has a recess, in particular a milling, preferably on the side facing the formwork skin, in which the temperature sensor is at least partially arranged.

[0025] Positioning the temperature sensor, at least partially, within a recess in the core of the formwork panel allows for space-saving integration of the sensor directly into the formwork panel. Furthermore, this avoids unevenness in the formwork surface.

[0026] Preferably, the temperature sensor is attached to the core of the panel. This ensures that the temperature sensor remains functional during the use of the formwork element. remains in a fixed location and temperature measurements can always be taken at the same spot.

[0027] In a further advantageous embodiment of the heated formwork element, the temperature sensor and / or the heating element is at least partially arranged in the formwork skin.

[0028] Thus, the formwork skin, together with the temperature sensor and / or the heating element, can be designed as a single layer.

[0029] In a further advantageous embodiment of the heated formwork element, the formwork plate has an electrical contact element in the area of ​​opposite end faces, wherein the heating element extends between the electrical contact elements and wherein the electrical contact elements electrically contact the heating element.

[0030] Preferably, the heating element is electrically contacted in segments across the entire surface of the heated formwork element. This makes it possible to create cutouts in the entire heated formwork element while still ensuring heating.

[0031] In a further advantageous embodiment of the heated formwork element, it has as a further component a frame structure which reinforces the formwork panel on a rear side of the formwork panel, wherein the control unit is preferably arranged in a space formed by the frame structure.

[0032] The frame structure increases the stability of the heated formwork element and absorbs the mechanical load acting upon it, or rather, supports the heated formwork element. Positioning the control unit in a space formed by the frame structure allows for space-saving and secure integration of the control unit into the heated formwork element.

[0033] In another advantageous embodiment of the heated formwork element, the control unit does not protrude significantly beyond the frame structure.

[0034] A control unit protruding beyond the frame structure of the heated formwork element could disrupt operations on the construction site; moreover, the control unit could easily be damaged. By arranging the control unit in a space formed by the frame structure, whereby the control unit does not protrude significantly beyond the frame structure, it can be ensured that the control unit does not impair operation on the construction site; in addition, the frame structure provides appropriate protection for the control unit.

[0035] In a further advantageous embodiment of the heated formwork element, the control unit has a power supply to convert an electrical input voltage into an output voltage, wherein the control unit preferably outputs to the heating element a maximum electrical output voltage of about 45 V to 50 V, in particular about 48 V, or a maximum output current of about 15 A to 25 A, in particular about 20 A, preferably a maximum electrical output voltage of about 45 V to 50 V, in particular about 48 V, and a maximum output current of about 15 A to 25 A, in particular about 20 A, most preferably a maximum electrical output voltage of about 50 V and a maximum output current of about 20 A.

[0036] Operating the heating element at low voltage enables energy-efficient use of the heated formwork element. Furthermore, operating the heating element at a voltage below the permissible continuous touch voltage for adults ensures safe use of the heated formwork element.

[0037] In a further advantageous embodiment of the heated formwork element, the control unit has at least two connections, each of which is designed to be connected to a power and data transmission connection, in particular an electrical cable or a hose.

[0038] This allows the heated formwork elements to be connected to a power distributor for energy and data transmission via power and data connections, in particular electrical cables for electrical energy or hoses for thermal energy. In the case of two connections, the individual control units of different heated formwork elements can also be interconnected via power and data transmission connections, in particular electrical cables or hoses. In this case, only one control unit of the first formwork element needs to be connected to a power distributor. Further control units of other formwork elements can be connected from this control unit. Depending on the number of connections of the control unit of the first The formwork elements and the control units of the subsequent formwork elements can preferably all be connected to the first formwork element or, more preferably, to each other in a series circuit. Hybrid configurations are also preferably possible, in which some formwork elements are connected in series to the control unit of the first formwork element and some are connected in series starting from the control unit of the first formwork element. Connecting further formwork elements in series reduces the number of cables or hoses to the power distribution unit, thus saving material and improving organization on a construction site. In particular, the individual control units can be connected modularly, enabling flexible use of the formwork elements.

[0039] In a further advantageous embodiment of the heated formwork element, the control unit has a housing which provides at least water resistance according to IPX5 and / or at least protection against contact according to IP6X.

[0040] A minimum level of water resistance and touch protection of the control unit housing ensures the safe use of the control unit and thus the heated formwork element on a construction site under the prevailing conditions and under possible different environmental influences.

[0041] In an advantageous embodiment of the formwork system, the heated formwork elements are at least partially arranged in groups of two to ten, in particular four, heated formwork elements, whose control units are connected to each other in an electrical series circuit.

[0042] Preferably, only a single control unit of the group of heated formwork elements is electrically connected to the power distributor. This allows for more flexible positioning of the individual heated formwork elements, as not every control unit of the heated formwork elements in a group of heated formwork elements needs to be connected to the power distributor.

[0043] In a further advantageous embodiment of the formwork system, the energy distributor can be connected to the control units of the majority of heated formwork elements, in particular via the energy and data transmission connection, and has a control unit to specify a setpoint temperature to be regulated for the switching regulator to the control units.

[0044] This makes it possible for all control units of the majority of heated formwork elements of the formwork system to be given a target temperature to be regulated for the switching regulator from a central point via the control unit of the energy distributor, without having to individually specify a target temperature to be regulated for the switching regulator to the control unit of each individual heated formwork element.

[0045] Preferably, the target temperature to be set specifies a temperature at the surface of the formwork skin. Since the temperature sensor of a heated formwork element also indicates a temperature at the surface of the formwork skin, this allows for a better comparison between the actual temperature measured by the temperature sensor and the target temperature to be set.

[0046] Preferably, the control unit is configured to specify an individually adjustable target temperature for each control unit of the majority of formwork elements in the formwork system. This ensures that the temperature at different formwork elements, which may have different concrete curing conditions, can be adapted to the prevailing conditions.

[0047] In a further advantageous embodiment of the formwork system, a temperature curve, in particular a time-dependent curve, for the target temperature to be regulated can be stored in the switching regulator and / or in the control unit.

[0048] This allows the formwork system to optimally control the temperature profile of the heated formwork elements and thus the curing of the concrete. A temperature curve for the desired target temperature can be stored, so that the formwork system automatically compares the actual temperature measured by the temperature sensor with the target temperature specified by the stored temperature curve and, if necessary, adjusts the actual temperature to the target temperature using the heating element.

[0049] Preferably, the temperature curve corresponds to a target temperature profile during the setting and hardening of the concrete, simulated or modeled depending on the concrete mix, the outside temperature and / or a desired stripping time.

[0050] Temperature plays a crucial role in the setting of concrete, as it significantly influences the course of the hydration process and thus the development of strength. Generally, the exothermic chemical process of cement hydration begins at temperatures above approximately 5 °C, which is considered the critical lower limit for activation. However, with modern, low-emission concretes, a higher minimum temperature of around 15 °C is often required to ensure a reliable and uniform reaction.

[0051] To control this process, a temperature curve is programmed to map the concrete's curing process. This curve takes into account both the concrete's own heat generation due to hydration and the applied heating power. The goal is to select the target temperature and adjust the heating power accordingly to ensure sufficient and uniform heat generation, enabling the desired strength development by the target formwork removal time. The concrete mix design, component geometry, and ambient temperature all play a crucial role in this process.

[0052] The temperature curve is preferably designed to gradually reduce the heating power in order to minimize thermal stresses and thus the risk of drying cracks. A continuously regulated heating power is significantly more advantageous than frequent switching on and off, as abrupt temperature changes can cause stresses in the young concrete.

[0053] Especially when outside temperatures fluctuate, it is important that the heating system reacts flexibly and switches on or off automatically to maintain the desired temperature curve. This supports a uniform and controlled setting process, which ultimately contributes to high concrete density and durability.

[0054] Another aspect of controlling the concrete curing process is predicting daytime and nighttime temperatures. By forecasting expected outside temperatures, the heating strategy can be proactively adjusted. For example, if cold spells are predicted at night, the flow temperature or heating output is increased in time to prevent temperature drops in the concrete. Similarly, if mild daytime temperatures are forecast, the heating output can be reduced to save energy and prevent overly rapid heating, which could lead to thermal stresses. This predictive control significantly improves the quality and uniformity of the curing process.

[0055] Furthermore, differentiated control of individual formwork elements in the base area and / or at corners and edges of the formwork compared to the center can be implemented. At the formwork edges, such as corners and edges, particularly in the base area, the concrete cools down significantly faster because a larger surface area is exposed to heat exchange with the environment. This can lead to temperature gradients within the component, which promote stress and, consequently, cracking. Therefore, increased heating power or additional temperature monitoring is often provided in these areas. In contrast, the center of the component retains heat longer due to its larger volume and smaller surface area relative to its mass. Zonal control, which allocates more heating power to the edge areas than to the center of the component, thus ensures a more homogeneous temperature distribution and significantly reduces the risk of cracking.

[0056] In a further advantageous embodiment of the formwork system, the energy distributor also has a user interface on which the target temperature to be regulated or a temperature curve for the target temperature to be regulated, in particular a time-dependent one, can be set.

[0057] This allows a user to centrally specify a target temperature for the switching controllers of all control units of the majority of heated formwork elements in the formwork system via the user interface of the power distributor. Preferably, the user interface offers the user the option of specifying an individually adjustable target temperature or a temperature curve, particularly a time-dependent one, for each individual control unit of the majority of formwork elements in the formwork system.

[0058] In a further advantageous embodiment of the formwork system, it also features: Means for calculating a target temperature to be regulated depending on the type of concrete used for concreting and an outside temperature and / or a time-dependent temperature curve for the target temperature to be regulated.

[0059] This allows for the individual calculation of a target temperature and / or a time-dependent temperature curve for the target temperature to be regulated for a wide variety of scenarios, i.e., for a wide variety of concrete types used for concreting and a wide variety of outside temperatures. These individually calculated target temperatures and / or time-dependent temperature curves for the The target temperatures to be regulated can then be specified to the individual control units of the majority of formwork elements of the formwork system.

[0060] In a further advantageous embodiment of the formwork system, it further comprises a remote control which has the means for calculation and a first data interface, wherein the control unit and / or the power distributor also has a second data interface on which the setpoint temperature to be regulated can be set, and wherein the remote control can be connected to or is connected to the control unit and / or the power distributor in order to transmit the setpoint temperature to be regulated and / or the time-dependent temperature curve for the setpoint temperature to be regulated.

[0061] This allows a user to calculate a target temperature and / or a time-dependent temperature curve for the target temperature from a certain distance from the formwork system and to transmit this either directly to the control units of the majority of formwork elements and / or to the energy distributor of the formwork system.

[0062] Preferably, the first and second data interfaces can be wirelessly connected or linked, particularly according to the Bluetooth standard. This eliminates the need for a connecting cable between the first and second data interfaces, reducing the complexity of the formwork system. This allows the user to wirelessly transmit a target temperature and / or a time-dependent temperature curve for that target temperature, giving the user greater flexibility regarding the location from which they specify the target temperature and / or the time-dependent temperature curve.

[0063] In a further advantageous embodiment of the formwork system, it further comprises a cloud server with computational means, wherein the control unit and / or the power distributor have a third data interface, wherein the cloud server can be connected or is connected to the control unit and / or the power distributor via the third data interface in order to transmit the setpoint temperature to be regulated and / or the time-dependent temperature curve for the setpoint temperature to be regulated.

[0064] Preferably, the cloud server and the third data interface can be wirelessly connected or linked via signal transmission, in particular according to a mobile communication standard. or a long-range wireless network, preferably LoRa. The control unit and / or the power distributor can thus be configured with a target temperature and / or a time-dependent temperature curve for the target temperature, without requiring a user to be in the immediate vicinity of the formwork system. This allows numerous users located in various places to access the cloud server and configure a target temperature and / or a time-dependent temperature curve for the target temperature.

[0065] In an advantageous embodiment, the method according to the third aspect of the invention additionally comprises the following step: measuring a pressure on the workpiece side by means of a pressure sensor, wherein the heating power of the heating element is additionally controlled as a function of the pressure measured by the pressure sensor. Accordingly, the formwork element according to the first aspect and / or the formwork system according to the second aspect can have a pressure sensor.

[0066] The pressure sensor measures the hydrostatic pressure of the liquid concrete in a concrete formwork. A decrease in pressure indicates that the concrete is hardening. Therefore, by using such a pressure sensor, the degree of hardening can be determined not only by temperature or the heat introduced into the concrete, but also by a measurement parameter that directly depends on the degree of hardening. This allows for even more precise control of the heating elements.

[0067] The invention will be explained in more detail below with reference to non-limiting embodiments illustrated in the figures. These figures show, at least partially schematically: Fig. 1 shows a perspective view of an embodiment of a heated formwork element; Fig. 2a shows a cross-sectional view of an embodiment of a heated formwork element; Fig. 2b shows a cross-sectional view of another embodiment of a heated formwork element; Fig. 2c shows a cross-sectional view of another embodiment of a heated formwork element; Fig. 2d shows a cross-sectional view of another embodiment of a heated formwork element; Fig. 3 shows a representation of the individual components of an exemplary embodiment of a formwork system; Fig. 4 shows an exemplary representation of the arrangement and interconnection of the individual components of an embodiment of a formwork system; and Fig. 5 shows a block diagram of an embodiment of a method for controlling the concrete temperature when concreting structural elements using a heated formwork element or a formwork system.

[0068] Fig. 1 schematically shows a preferred embodiment of a heated formwork element 1 according to the present invention in a perspective view.

[0069] The heated formwork element 1 comprises a formwork panel 2, which has a formwork skin 3, a heating element 4, a panel core 5 and at least one temperature sensor 6, a control unit 7 with a switching regulator 8, and a frame structure 9, which is not shown for the sake of clarity.

[0070] The formwork panel 2 is constructed in layers from the panel core 5, the heating element 4, and the formwork skin 3, with the panel core 5 comprising the majority of the thickness of the formwork panel 2. Specifically, the panel core 5 can have a thickness of approximately 18 mm, and the formwork skin 3 and the heating element 4 each have a thickness of approximately 1 mm.

[0071] The core 5 is preferably made of wood or plastic. Its primary purpose is to absorb and / or support a mechanical load acting on the heated formwork element 1. The core 5 also preferably serves to insulate the workpiece side 11 of the heated formwork element 1, which is heated by the heating element 4, from the cold environment.

[0072] The formwork skin 3 is also preferably made of wood. Alternatively, the formwork skin 3 can also be made of another material, such as a metal or alloy, e.g., aluminum or steel, or a suitable plastic.

[0073] In this embodiment, the heating element 4 is designed as a heating fleece that extends over the entire formwork panel 2. This enables the concrete to be heated uniformly across the entire surface of the heated formwork element 1, thus ensuring uniform hardening of the concrete. The formwork panel 2 has electrical contact elements (13A, 13B) that electrically contact the heating fleece 4. The formwork panel 2 can, for example, have one electrical contact element (13A, 13B) at each of its opposite end faces. The heating fleece 4 extends between the electrical contact elements (13A, 13B), which electrically contact the heating fleece 4. Alternatively, the formwork panel 2 can also have electrical contact elements (13A, 13B, ...) over its entire surface, which electrically contact the heating fleece 4 in segmented sections.

[0074] The temperature sensor 6 is configured to measure a temperature on the workpiece side 11 at the surface of the formwork skin 3, either directly or indirectly. The temperature sensor 6 is preferably a thermocouple, a resistance sensor, or a thermistor. The temperature sensor 6 is preferably attached to the plate core 5, wherein the heated formwork element 1 further preferably has a recess on the formwork skin. The heating element 4 has a recess at the position of the temperature sensor 6 on the side facing the formwork skin 3 (Fig. 2b). The temperature sensor 6 is also preferably located in the formwork skin 3 (Fig. 2b) or at least partially in a recess of the plate core 5 on the side facing the formwork skin 3 (Fig. 2a). Preferably, the heating element 4 has a recess at the position of the temperature sensor 6. Furthermore, preferably, the heating element can be located in the formwork skin 3 on the side facing the formwork skin 3 (Fig. 2b). 4 then be arranged in this recess (Fig. 2c).

[0075] In an alternative embodiment, the temperature sensor 6 can also be directly embedded in the concrete. Preferably, the temperature sensor 6 is embedded on the surface 11 of the formwork skin 3 or at a distance from the surface 11. An embedded temperature sensor 6 achieves the highest measurement accuracy. However, an embedded temperature sensor 6 is generally no longer removable after the formwork is removed – the temperature sensor 6 is then a so-called “lost sensor”.

[0076] The control unit 7 with the switching regulator 8 is mounted on the back 12 of the formwork panel 2 and is preferably wirelessly connected to the temperature sensor 6. Depending on the actual temperature measured by the temperature sensor 6 and a predetermined setpoint temperature, the heating power of the heating fleece 4 can be regulated by the control unit 7 and the switching regulator 8 in order to adjust the actual temperature of the hardening concrete to the setpoint temperature.

[0077] The heated formwork element 1 can additionally have an opening 14, which extends from the rear 12 of the heated formwork element 1 to the workpiece side 11, so that the temperature sensor 6 or additionally another temperature sensor 15 (not shown), which is in contact with the concrete and / or can protrude into the concrete and can measure a temperature of the concrete directly at a surface of the concrete, can be passed through it (Fig. 2d).

[0078] Additionally, the heated formwork element 1 can have a pressure sensor that measures the pressure exerted by the concrete on the workpiece side 11 against the heated formwork element 1, thus providing information on how quickly the concrete can be poured into the heated formwork element 1 without exceeding a maximum pressure specified for the heated formwork element 1. Based on the pressure measurements, it can be verified whether the heating power of the heating fleece 4, regulated by the control unit 7 and the switching regulator 8, produces the desired hardening effect of the concrete.

[0079] If the formwork element 1 additionally includes a further temperature sensor 15 that can protrude into the concrete and measure the temperature of the concrete directly on its surface, the control unit 7 is also preferably wirelessly connected to this further temperature sensor 15. Depending on the actual temperature measured by the temperature sensor 6 on the surface of the formwork skin 3 and / or the actual temperature measured by the further temperature sensor 15 directly on the surface of the concrete, and a predetermined setpoint temperature, the heating power of the heating fleece 4 can be regulated by the control unit 7 and the switching controller 8 in order to adjust the actual temperature of the hardening concrete to the setpoint temperature.

[0080] Additionally, the heated formwork element 1 can include another layer on its back side 12, which, for example, has printed designs for advertising purposes. Alternatively, the heated formwork element 1 can also be designed to be mirror-symmetrical with respect to the core 5, i.e., the heated formwork element 1 includes a second heating element 4, a second formwork skin 3, and at least one additional temperature sensor 6 on its back side 12, which is also preferably wirelessly connected to the control unit 7 and the switching regulator 8. A symmetrical design of the heated formwork element 1 allows for longer service lives before it needs to be completely replaced, since in the event of a worn formwork skin 3, the heated formwork element 1 can simply be turned over. then, when the heated formwork element 1 is used as intended, concrete is in contact with the second formwork skin 3 located on the back 12.

[0081] Fig. 2a shows a cross-sectional view of an embodiment of a heated formwork element 1 according to the present invention. Unless otherwise described, this embodiment is identical in construction to the embodiment of a heated formwork element 1 shown in Fig. 1, in particular with regard to the components and their arrangement.

[0082] In this embodiment shown in Fig. 2a, the plate core 5 has a recess on the side facing the formwork skin 3, in which the temperature sensor 6 is at least partially arranged. The temperature sensor 6 is thus arranged at least substantially at the interface between the plate core 5 and the heating element 4.

[0083] This embodiment has the advantage that the temperature sensor 6 can be attached directly to the core of the plate 5. This ensures that the temperature sensor 6 remains in a fixed position during the use of the formwork element 1 and that temperature measurements can always be taken at the same location.

[0084] Fig. 2b shows a cross-sectional view of a further embodiment of a heated formwork element 1 according to the present invention. Unless otherwise described, this embodiment is identical in construction to the embodiment of a heated formwork element 1 shown in Fig. 1, in particular with regard to the components and their arrangement.

[0085] In this embodiment, the formwork skin 3 has a recess on the side facing the heating element 4, in which the temperature sensor 6 is at least partially arranged. The temperature sensor 6 is thus arranged at least substantially at the interface between the formwork skin 3 and the heating element 4.

[0086] This embodiment has the advantage that the temperature sensor 6 is located close to the hardening concrete and thus the temperature of the hardening concrete can be measured accurately.

[0087] Fig. 2c shows a cross-sectional view of a further embodiment of a heated formwork element 1 according to the present invention. Unless otherwise stated, As described, this embodiment is structurally identical to the embodiment of a heated formwork element 1 shown in Fig. 1, in particular with regard to the components and their arrangement.

[0088] In this embodiment, the heating element 4 has a recess on the side facing the plate core 5 at the position of the temperature sensor 6, in which the temperature sensor 6 is at least partially arranged. The temperature sensor 6 is thus located at least substantially at the interface between the heating element 4 and the plate core 5. Alternatively, the heating element 4 can also have a recess on the side facing the formwork skin 3 at the position of the temperature sensor 6, in which the temperature sensor 6 is at least partially arranged. In this case, the temperature sensor 6 is located at least substantially at the interface between the heating element 4 and the formwork skin 3.

[0089] This embodiment has the advantage that the temperature sensor 6 can be attached directly to the core of the formwork panel 5. This ensures that the temperature sensor 6 remains in a fixed position during the use of the formwork element 1 and that temperature measurements can always be taken at the same location. Furthermore, this embodiment has the advantage that the temperature sensor 6 is positioned close to the hardening concrete, thus allowing for precise measurement of the concrete's temperature.

[0090] Fig. 2d shows a cross-sectional view of a further embodiment of a heated formwork element 1 according to the present invention. Unless otherwise described, this embodiment is identical in construction to the embodiment of a heated formwork element 1 shown in Fig. 1, in particular with regard to the components and their arrangement.

[0091] In this embodiment, the heated formwork element 1 has an opening 14 extending from the rear side 12 of the heated formwork element 1 to the workpiece side 11. The temperature sensor 6 or another sensor 15, in particular another temperature sensor or a pressure sensor, which passes through the opening 14, can be in contact with the concrete through the opening 14 and / or protrude into the concrete and measure a temperature or pressure of the concrete directly on the surface of the concrete or within the concrete. The opening can be provided at the factory or flexibly created by drilling into the formwork element 1 on site. In particular, the heating element 4 is designed in such a way that its function is not disrupted by the introduction of a hole.

[0092] This embodiment has the advantage that the temperature sensor 6 or the additional temperature sensor 15 projects into the concrete and measures the temperature of the concrete directly on its surface or within its interior, thus enabling precise measurement of the temperature of the hardening concrete. Furthermore, the temperature sensor 6 or the additional temperature sensor 15, which passes through the opening 14 extending from the rear side 12 of the heated formwork element 1 to the workpiece side 11, remains easily accessible from the rear side 12 of the heated formwork element 1 even during its use.

[0093] Fig. 3 shows a schematic representation of the individual components of an embodiment of a formwork system 20 according to the present invention.

[0094] The formwork system 20 comprises a plurality of heated formwork elements 1. For the sake of clarity, only a single heated formwork element 1 is shown. Unless otherwise noted, the properties and advantages of the embodiments of a heated formwork element 1 shown in Figs. 1, 2a, 2b, 2c and 2d apply analogously to the heated formwork elements 1 of the formwork system 20 from Fig. 3.

[0095] The heated formwork elements 1 of the formwork system 20 comprise, as shown in Figs. 1, 2a, 2b and 2d, a formwork panel 2 having a formwork skin 3, a heating element 4, a panel core 5 and at least one temperature sensor 6, a control unit 7 with a switching regulator 8, and a frame structure 9. For the sake of clarity, not all components of the heated formwork element 1 shown are depicted.

[0096] The formwork system 20 further comprises a power distributor 21, which is connected to the heated formwork elements 1 via electrical cables 10 for power and data transmission. The power distributor 21 supplies the heated formwork elements 1 with electrical energy.

[0097] The energy distributor 21 preferably has a control unit 22 to specify a setpoint temperature for the switching regulator 8 to be regulated by the control units 7. Preferably, the control unit 22 is configured to specify an individual setpoint temperature for the respective switching regulator 8 to each control unit 7.

[0098] The energy distributor 21 further preferably has a user interface 23 on which the target temperature to be regulated or a temperature curve, in particular a time-dependent one, for the target temperature to be regulated can be set. Preferably, a target temperature to be regulated or a temperature curve, in particular a time-dependent one, for the target temperature to be regulated can be set individually for each control unit 7 on the user interface 23.

[0099] The formwork system 20 preferably further comprises means 24 for calculating a target temperature to be set as a function of the concrete used for concreting and an outside temperature and / or a time-dependent temperature curve for the target temperature to be set. Preferably, the means 24 are configured to calculate a target temperature to be set as a function of the concrete used for concreting and an outside temperature and / or a time-dependent temperature curve for the target temperature to be set individually for each control unit 7.

[0100] Furthermore, the formwork system 20 preferably includes a remote control 25, which has the means 24 for calculating a target temperature to be set as a function of the concrete used for concreting and an outside temperature and / or a time-dependent temperature curve for the target temperature to be set. In addition, the remote control preferably has a first data interface.

[0101] The energy distributor 21 preferably has a second data interface on which the target temperature to be regulated can be set. The first data interface of the remote control 25 is preferably wirelessly connected to the second data interface of the energy distributor 21, in particular via Bluetooth, to transmit the target temperature and / or a time-dependent temperature curve for the target temperature. The remote control 25 can be, in particular, a smartphone, a tablet, or a computer.

[0102] Alternatively or additionally, the control units 7 of the heated formwork elements 1 can also have a second data interface on which the setpoint temperature to be regulated can be set, wherein the first data interface of the remote control 25 is preferably wirelessly connected to the second data interface of the control units 7, in particular according to the Bluetooth standard, in order to transmit the setpoint temperature to be regulated and / or a time-dependent temperature curve for the setpoint temperature to be regulated, either alternatively or additionally.

[0103] Furthermore, the formwork system 20 has a cloud server 26 which has the means 24 for calculating a target temperature to be set depending on a concrete used for concreting and an outside temperature and / or a time-dependent temperature curve for the target temperature to be set.

[0104] The energy distributor 21 has a third data interface, wherein the cloud server 26 is wirelessly connected to the energy distributor 21 via the third data interface using a mobile communication standard to transmit the setpoint temperature and / or the time-dependent temperature curve for the setpoint temperature.

[0105] Alternatively or additionally, the control units 7 of the heated formwork elements 1 can also have a third data interface, wherein the cloud server 26 is wirelessly connected to the control units 7 via the third data interface using a mobile communication standard to transmit the setpoint temperature and / or the time-dependent temperature curve for the setpoint temperature.

[0106] Alternatively, the second and third data interfaces of the energy distributor 21 and / or the control units 7 of the heated formwork elements 1 can also be configured as a single data interface, wherein the energy distributor 21 and / or the control units 7 of the heated formwork elements 1 can be wirelessly connected or linked via this single data interface to the remote control 25 via the first data interface and the cloud server 26, in particular according to a mobile communication standard, in order to transmit the setpoint temperature to be regulated and / or the time-dependent temperature curve for the setpoint temperature to be regulated.

[0107] Fig. 4 shows an exemplary representation of the arrangement and interconnection of the individual components of an embodiment of a formwork system 20 according to the present invention.

[0108] In the exemplary embodiment of a formwork system 20 from Fig. 4, the formwork system 20 comprises twenty-four individual heated formwork elements 1. Unless otherwise noted, the properties and advantages of the embodiments of a heated formwork element 1 shown in Figs. 1, 2a, 2b, 2c and 2d, or the properties and advantages of the embodiment of a formwork system 20 shown in Fig. 3, apply analogously to the heated formwork elements 1 or to the formwork system 20 from Fig. 4.

[0109] The heated formwork elements 1 of the formwork system 20, as shown in Figs. 1, 2a, 2b, 2c, 2d and 3, each comprise a formwork panel 2, which includes a formwork skin 3, a heating element 4, a panel core 5 and at least one temperature sensor 6, a control unit 7 with a switching regulator 8, and a frame structure 9. For the sake of clarity, not all components of the heated formwork elements 1 shown are depicted.

[0110] The heated formwork elements 1 of the formwork system 20 are arranged in six separate groups of four heated formwork elements 1 each, the control units 7 of which are connected to each other in an electrical series circuit. This means that the power distributor 21 is connected via electrical cables 10 to the control units 7 of a total of six "first" heated formwork elements 1a. The control unit 7 of each "first" heated formwork element 1a is connected via an electrical cable 10 to a control unit 7 of each "second" heated formwork element 1b. The control unit 7 of each "second" heated formwork element 1b is in turn connected via an electrical cable 10 to a control unit 7 of each "third" heated formwork element 1c. The control unit 7 of each “third” heated formwork element 1c is in turn connected via an electrical cable 10 to a control unit 7 of each “fourth” heated formwork element 1d.

[0111] The power distributor 21 of the formwork system 20 has a nominal input voltage of 400 V and a nominal input current of 32 A. Furthermore, the power distributor 21 includes a power supply unit to convert an electrical input voltage into an output voltage, whereby the power distributor 21 outputs a maximum electrical output voltage of approximately 230 V and a maximum output current of approximately 16 A to the control units 7.

[0112] The control unit 7 of each individual heated formwork element 1 has a power supply to convert an electrical input voltage into an output voltage, with the control unit 7 supplying to the heating element 4 a maximum electrical output voltage of about 50 V and a maximum output current of about 20 A.

[0113] Fig. 5 shows a block diagram of an embodiment of a method 100 for controlling a concrete temperature when concreting structural elements by means of a heated formwork element 1 or by means of a formwork system 20 according to the present invention.

[0114] In a first process step 101 of process 100, the temperature of the concrete on the workpiece side 12 of the heated formwork element 1 is measured using the temperature sensor 6. The temperature sensor 6 is preferably a temperature sensor 6 integrated into the heated formwork element 1.

[0115] This measured actual temperature of the concrete can then be compared with a predetermined target temperature of the concrete.

[0116] The comparison of the measured actual temperature of the concrete can be carried out, for example, with a target temperature of the concrete stored in the switching controller 8 of the heated formwork element 1 or in the control unit 22 of the energy distributor 21 of the formwork system 20, or with a temperature curve for the target temperature of the concrete to be regulated, in particular a time-dependent one.

[0117] Preferably, the measured actual temperature of the concrete is compared with a target temperature of the concrete to be regulated or a time-dependent temperature curve for the target temperature of the concrete to be regulated, which was calculated as a function of a concrete used for concreting and an outside temperature.

[0118] In a second process step 102 of process 100, the heating power of the heating element 4 of the heated formwork element 1 is then controlled as a function of the actual temperature of the concrete measured by the temperature sensor 6 and a predetermined setpoint temperature. In particular, the heating power of the heating element 4 of the heated formwork element 1 is controlled such that the measured actual temperature of the concrete is adjusted to the predetermined setpoint temperature of the concrete. Preferably, the heating power of the heating element 4 of the heated formwork element 1 is controlled such that the heating power of the heating element 4 is continuously or quasi-continuously reduced when the measured actual temperature of the concrete exceeds the predetermined setpoint temperature, and the heating power of the heating element 4 is continuously or quasi-continuously increased when the measured actual temperature of the concrete falls below the predetermined setpoint temperature.

[0119] It should be noted that the embodiments described are merely examples and are not intended to limit the scope of protection, application, or structure in any way. Rather, the preceding description provides a guideline for the skilled person to implement at least one embodiment, whereby Various modifications, particularly with regard to the function and arrangement of the described components, can be made without leaving the scope of protection, as can be seen from the claims and these equivalent combinations of features. Reference symbol list: 1 Heated formwork element 2 formwork panels 3 Shell skin 4 heating elements 5 plate core 6 Temperature sensor 7 Control unit 8 switching regulators 9 Framework structure 10 Energy and data transmission connection 11 Workpiece side 12 Back 13A, 13B electrical contact element 14 Opening 15 additional temperature sensors 20 formwork system 21 energy distributors 22 Control unit 23 User interface 24 methods for calculating the target temperature 25 Remote control 26 cloud servers

Claims

Patent claims 1. Heatable formwork element (1) for concreting structural components, comprising the following components: a formwork panel (2) with a formwork skin (3), a heating element (4), a panel core (5) and at least one temperature sensor (6), wherein a surface (11) of the formwork skin (3) forms a workpiece side of the formwork panel (2) at which, when the heated formwork element (1) concrete, wherein the heating element (4), in particular a heating fleece, heating wire or a heating tube, is arranged between the plate core (5) and the workpiece side and is configured to heat the formwork skin (3), wherein the plate core (5) absorbs and / or supports a mechanical load acting on the heatable formwork element (1), wherein the at least one temperature sensor (6) is configured to measure a temperature on the workpiece side;and a control unit (7) which is connectable to or has a signal transmission connection with the temperature sensor (6) and which has a switching regulator (8) for the heating element (4), wherein the control unit (7) is configured to regulate the heating power of the heating element (4) as a function of a temperature measured by the temperature sensor (6), and wherein the control unit (7) is arranged, in particular attached, on a side of the formwork element (1) facing away from the formwork skin (3) on the formwork panel (2) or another component of the formwork element (1).

2. Heatable formwork element (1) according to claim 1, wherein the temperature sensor is arranged at least partially between the workpiece side and a rear side of the formwork panel (2).

3. Heatable formwork element (1) according to claim 1 or 2, wherein the plate core (5) has a recess, in particular a milled recess, preferably on the formwork skin (3) facing side, in which the temperature sensor (6) is at least partially arranged.

4. Heatable formwork element (1) according to one of the preceding claims, wherein the temperature sensor (6) and / or the heating element (4) are arranged at least partially in the formwork skin (3).

5. Heatable formwork element (1) according to one of the preceding claims, wherein the formwork plate (2) has an electrical contact element (13A, 13B) in the area of ​​opposite end faces, wherein the heating element (4) extends between the electrical contact elements (13A, 13B) and wherein the electrical contact elements (13A, 13B) electrically contact the heating element (4).

6. Heatable formwork element (1) according to one of the preceding claims, which further comprises a frame structure (9) which reinforces the formwork panel (2) on a rear side of the formwork panel (2), wherein the control unit (7) is preferably arranged in a space formed by the frame structure (9).

7. Heatable formwork element (1) according to claim 6, wherein the control unit (7) does not project significantly beyond the frame structure (9).

8. Heatable formwork element (1) according to one of the preceding claims, wherein the control unit (7) has a power supply for converting an electrical input voltage into an output voltage, wherein the control unit (7) preferably outputs to the heating element (4) a maximum electrical output voltage of about 45 V to 50 V, in particular about 48 V, or a maximum output current of about 15 A to 25 A, in particular about 20 A, preferably a maximum electrical output voltage of about 45 V to 50 V, in particular about 48 V, and a maximum output current of about 15 A to 25 A, in particular about 20 A, most preferably a maximum electrical output voltage of about 50 V and a maximum output current of about 20 A.

9. Heatable formwork element (1) according to one of the preceding claims, wherein the control unit (7) has at least two connections, each of which is configured to be connected to a power and data transmission connection (10), in particular an electrical cable or a hose.

10. Formwork system (20), comprising: a plurality of, in particular 24, heated formwork elements (1) according to one of the preceding claims; and an energy distributor (21) which is configured to supply the control units (7) of the heated formwork elements (1) with energy, in particular electrical energy or thermal energy, wherein the heated formwork elements (1) and the energy distributor (21) can be connected or are connected for energy and data transmission by means of energy and data transmission connections (10), in particular electrical cables or hoses.

11. Formwork system (20) according to claim 10, wherein the heatable formwork elements (1) are at least partially arranged in groups of two to ten, in particular four, heatable formwork elements (1), the control units (7) of which are connected to each other in an electrical series circuit.

12. Formwork system (20) according to claim 10 or 11, wherein the energy distributor (21) is connectable or connected to the control units (7) of the plurality of heated formwork elements (1), in particular via the energy and data transmission connection (10), and has a control unit (22) to specify a setpoint temperature to be regulated for the switching controller (8) to the control units (7).

13. Formwork system (20) according to one of claims 10 to 12, wherein a temperature curve, in particular time-dependent, for the setpoint temperature to be regulated can be stored in the switching regulator (8) or in the control unit (22).

14. Formwork system (20) according to one of claims 12 or 13, further comprising: Means (24) for calculating a target temperature to be set as a function of the concrete used for concreting and an outside temperature and / or a time-dependent temperature curve for the target temperature to be set.

15. Method (100) for controlling a concrete temperature during the concreting of structural components by means of a heated formwork element (1) according to any one of claims 1 to 9 or by means of a formwork system (20) according to any one of claims 10 to 14, comprising the following steps: Measuring (101) a temperature on the workpiece side using the temperature sensor (6); and Rules (102) of a heating power of the heating element (4) depending on a temperature measured by the temperature sensor (6).

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