Cable-Driven Concrete Additive Manufacturing System
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Solution Overview
Problem
Current concrete additive manufacturing systems, such as gantry systems, are limited in fieldability due to complex setup requirements, high labor costs, and aesthetic appeal issues, leading to barriers in commercial implementation of on-site construction.
Innovation Solution
A cable-driven additive manufacturing system that eliminates the need for a gantry system, allowing for easy setup and transportation, using an end effector with linear translation capabilities along x, y, and z axes, suspended by aerial hoists and controlled by base stations, enabling efficient deposition of concrete or cementitious materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gantry systems are used for concrete additive manufacturing, then manufacturing precision and structural fabrication capability are improved, but device complexity and ease of operation deteriorate due to complicated setup and extensive site preparation requirements
Solution Approach 1:
The system divides the gantry structure into separate functional modules: motion-control base stations positioned at fixed locations, an aerial hoist for vertical positioning, and a cable system for motion transmission. This segmentation allows each component to be independently optimized and assembled on-site without requiring a complete gantry framework.
Solution Approach 2:
The invention extracts the essential motion-control functionality from the traditional gantry system, eliminating the need for extensive physical framework. Only the critical cable-driven actuation mechanism and base stations remain, significantly reducing setup complexity while maintaining positioning precision.
2Productivity
If traditional construction methods are used, then construction speed and cost-effectiveness are improved, but material waste and environmental harm increase
Solution Approach 1:
The additive manufacturing process enables continuous deposition of concrete material layer by layer, eliminating the start-stop nature of traditional block laying. This continuous fabrication reduces material waste through precise material placement and enables faster construction through automated, uninterrupted printing operations.
Solution Approach 2:
The system changes the fundamental parameter of material deposition from discrete block placement to continuous extrusion. This parameter change allows for optimized material usage, reduced waste, and the ability to create complex geometries that are more efficient in terms of material consumption and structural performance.
3Manufacturing precision
If gantry systems are deployed for on-site construction, then manufacturing capability is improved, but loss of time and site disruption increase due to extensive preparation requirements
Solution Approach 1:
The motion-control base stations are pre-positioned at predetermined locations around the construction site before fabrication begins. This preliminary positioning of control infrastructure eliminates the need for time-consuming on-site assembly of gantry structures, allowing immediate commencement of concrete printing operations.
Data Source
AI summary
A cable-driven additive manufacturing system includes an end effector configured for linear translation within a three-dimensional workspace, an aerial hoist suspending the end effector by at least one suspension cable, a plurality of base stations disposed below the aerial hoist, and control cables running from each of the base stations to the end effector.