Automatic Formwork System for Flexible Elastic Membrane Molds
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Solution Overview
Problem
Current formwork systems lack the ability to numerically control the geometry of flexible elastic membrane molds, preventing precise and repeatable molding of complex, sinuous shapes in concrete or similar materials with high aesthetic and architectural value.
Innovation Solution
An automatic formwork system with motorized mechanical support, comprising a modular arrangement of traction and thrust units, allows for numerical control of flexible elastic membrane molds, enabling precise configuration and correction of mold geometry during the molding process using linear actuators and sensors to match a pre-designed shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flexible elastic membrane molds are used to mold complex sinuous shapes, then manufacturing precision and aesthetic value are improved, but control over mold geometry and repeatability deteriorate
Solution Approach 1:
The patent applies dynamics by making the mold configuration adjustable and reconfigurable through motorized actuators. The supporting apparatus includes multiple actuators that can dynamically adjust the position and shape of the flexible membrane mold, transforming it from a static to a dynamically controllable system. This allows precise geometric control while maintaining the flexibility needed for complex sinuous shapes.
Solution Approach 2:
The patent implements feedback through sensors that detect the actual position and shape of the flexible membrane mold during the molding process. This feedback information is used by the control system to make real-time adjustments via the actuators, ensuring that the mold geometry matches the desired configuration with high precision and repeatability.
2Manufacturing precision
If motorized actuators are added to control flexible mold geometry, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the supporting apparatus into multiple independent actuator units distributed along the mold. Each actuator can be controlled independently, allowing precise local adjustments to the flexible membrane geometry. This modular approach enables complex shape control while keeping individual actuator units relatively simple and manageable.
Solution Approach 2:
The patent implements universality by designing a standardized actuator and sensor module that can be repeatedly used along the entire length of the flexible mold. This multi-functional module serves multiple purposes: positioning, shaping, and sensing. By reusing the same modular components throughout the system, the overall device complexity is reduced despite the sophisticated functionality required.
3Measurement precision
If multiple actuators are used to push pistons under the flexible mold, then mold position control is improved, but the system only works for laminar parts limiting adaptability
Solution Approach 1:
The patent applies dimensionality change by transitioning from a single-sided actuation system (pushing from below for laminar parts) to a multi-directional system. The actuators are positioned to apply forces from multiple directions and locations, enabling control of the flexible membrane in three-dimensional space. This allows the mold to form complex non-laminar geometries with varying cross-sections and sinuous shapes, greatly expanding the system's adaptability.
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 system ensures precision and repeatability in molding complex shapes, facilitating the production of high-quality, sinuous surface parts with improved dimensional accuracy and ease of demolding, overcoming the limitations of artisanal methods.
Implementation Method 1
each of the traction units is composed of a first linear actuator and the second linear actuator horizontally arranged and a third linear actuator vertically arranged
Implementation Method 2
an elastic membrane supported by a plurality of supporting modules... the elastic membrane is previously deformed according to an approximation to the previous design of a part to be molded
Implementation Method 3
enabling movement in their respective positions on a horizontal sliding platform... numerical control of flexible elastic membrane molds
Data Source
AI summary
Flexible molds have an elastic membrane supported by modules, arranged next to one another along a horizontal longitudinal axis of the mold. Each module has traction units, each forming a respective group with a respective thrust unit, with the groups arranged opposite one another at a preset distance. Pairs of traction units are arranged opposite one another in a direction perpendicular to the axis, and the respective thrust units thereof are arranged therebetween. The modules hold the membrane with the mold via reinforced eyelets distributed on both edges parallel to the axis. Each traction unit has linear actuators arranged horizontally and another linear actuator arranged vertically, which together enable movement. The membrane is previously deformed according to an approximation of the prior design of a part to be molded, and prestressed according to a mathematical prediction of the deformation thereof after receiving a conglomerate in liquid or plastic state.