Additive Layering for Cast-Concrete Walls
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Solution Overview
Problem
Conventional concrete construction methods require expensive forming processes and robotic systems, leading to high costs and low production rates, especially for cast-in-situ concrete structures like walls and towers, where the need for digital models and precise robotic control is cumbersome and costly.
Innovation Solution
The development of automatic geometry control systems for additive layering of concrete, which allows for the creation of complex geometries without the need for digital models or robotic systems, using conventional plant-batched concrete and onsite mixing, enabling faster construction rates and reduced costs by avoiding the need for specialized mixes and forming processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming processes and robotic systems are used for cast-in-situ concrete structures, then structural integrity and precision can be achieved, but construction costs increase and production rates decrease
Solution Approach 1:
The patent changes the rheological parameters of concrete by developing zero-slump pumpable concrete with specific viscosity and flow characteristics. This allows the concrete to be pumped through hoses to remote locations while maintaining shape stability during placement, enabling faster construction without sacrificing geometric precision
Solution Approach 2:
The patent extracts and eliminates the need for expensive robotic systems and digital modeling by using a simplified approach where zero-slump concrete is pumped directly into forms. The concrete's self-setting properties replace the need for complex robotic placement and digital control systems
2Strength
If conventional forming processes are used for cast-in-situ concrete, then structural integrity is maintained, but construction costs increase
Solution Approach 1:
The patent modifies the chemical and rheological parameters of concrete to create a zero-slump mix that maintains structural integrity while reducing the need for expensive forming processes. The altered concrete composition allows for simpler, faster placement methods
Solution Approach 2:
The patent employs disposable or simple forms rather than expensive, complex forming systems. The zero-slump concrete's rapid setting特性 allows the use of simpler forms that can be quickly installed and removed, reducing overall construction costs while maintaining structural quality
3Manufacturing precision
If digital models and robotic control systems are implemented, then geometric precision can be achieved, but device complexity and costs increase
Solution Approach 1:
The patent removes the complex digital modeling and robotic control systems entirely, replacing them with a straightforward process of pumping zero-slump concrete into forms. The concrete's inherent properties provide the geometric accuracy without requiring complex control systems
Solution Approach 2:
The zero-slump concrete essentially performs the positioning and shaping function itself through its unique rheological properties - it flows into the form when pumped but immediately stabilizes, eliminating the need for external robotic positioning and digital control
Data Source
AI summary
One aspect of the present invention pertains to methods of forming concrete structures. Another aspect of the present invention pertains to systems for forming concrete structures. Another aspect of the present invention pertains to devices forming concrete structures.