3D Printed Plant Foundation Automation
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Solution Overview
Problem
The construction of plant foundations is inefficient and unsafe due to the labor-intensive and time-consuming traditional casting methods, which require a large number of workers and pose safety risks.
Innovation Solution
A method using a 3D printer to form reinforced-concrete foundations with integrated material joining of concrete and metal, allowing for the creation of flow paths and sparse structures, thereby automating the foundation manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional casting methods are used to form foundations, then foundations can be formed with conventional materials and processes, but the construction period is extended and the number of workers required increases
Solution Approach 1:
The patent replaces traditional mechanical casting processes with 3D printing technology. The 3D printer deposits concrete material layer by layer under computer control to form foundation structures, eliminating the need for formwork, manual labor, and traditional curing processes. This substitution of mechanical systems with automated additive manufacturing dramatically reduces construction time and increases productivity.
Solution Approach 2:
The patent changes the fundamental parameters of foundation construction by transitioning from subtractive or formwork-based methods to additive manufacturing. The 3D printing process allows for continuous material deposition, optimized layer thickness, and automated layer-by-layer construction, fundamentally altering the construction parameters to achieve faster foundation formation with fewer workers.
2Ease of manufacture
If traditional casting methods are used to form foundations, then foundations can be formed using conventional processes, but the number of construction workers increases and safety risks arise
Solution Approach 1:
The patent replaces dangerous manual operations in traditional casting with automated 3D printing systems. The automated deposition of concrete material eliminates exposure to heavy lifting, formwork handling, and working at heights, thereby reducing safety risks while maintaining ease of manufacture through automated processes.
Solution Approach 2:
The 3D printing system performs foundation construction autonomously through automated material deposition and layer-by-layer construction. The system self-regulates the construction process, eliminating the need for multiple workers to coordinate dangerous tasks, thereby reducing safety risks while maintaining manufacturing capability.
3Extent of automation
If 3D printer is used to form foundation, then the number of construction workers is reduced and safety is improved, but new technology implementation complexity arises
Solution Approach 1:
The patent employs a 3D printing system designed to perform multiple functions: depositing concrete material, forming various foundation geometries, and potentially integrating reinforcement elements. This multi-functional approach consolidates what would otherwise require separate processes and equipment, making the automated system more manageable despite its complexity.
Solution Approach 2:
The patent utilizes composite material approaches in the 3D printing process, combining concrete with embedded reinforcement elements or integrating multiple material properties within the foundation structure. This allows the automated system to create complex composite structures that would be difficult to achieve with traditional methods, justifying the technology implementation complexity.
4Productivity
If 3D printer is used to form foundation, then construction efficiency is improved and labor requirements are reduced, but manufacturing process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the foundation construction into discrete layers that are deposited sequentially by the 3D printer. This layer-by-layer approach simplifies the control of the manufacturing process, allowing for standardized deposition parameters and easier quality control, thereby managing process complexity while maintaining high productivity.
Solution Approach 2:
The patent employs preliminary action through digital modeling and path planning before the actual 3D printing process. The foundation geometry is pre-programmed, and the deposition path is calculated in advance, which simplifies the execution phase and reduces real-time decision complexity, thereby enabling high-speed construction with manageable process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the need for manual labor, enhances safety, and accelerates the construction process by enabling efficient and automated foundation formation.
Implementation Method 1
forming a foundation, by a 3D printer, in a ground for installation of a device
Implementation Method 2
the foundation having the RC structure is integrally formed through different material joining of a concrete material and a metal material
Data Source
AI summary
To provide a technology for manufacturing a foundation of a plant efficiently and safely. Provided is a method for manufacturing a foundation (6) to be provided in a plant configured to process fluid, the method including a step of forming a foundation, by a 3D printer, in a ground for installation of a device to be provided in the plant, or in a ground for installation of a framework structure configured to support the device or a piping through which the fluid flows, the foundation being configured to support the device or the framework structure.