Cable-Suspended Extrusion Head for Large-Scale 3D Building Construction
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Solution Overview
Problem
Existing 3D printing technologies face challenges in achieving precise positioning of large-scale structures, particularly in the vertical direction, which is crucial for constructing large buildings, as conventional methods require rigid scaffolding or gantry systems that are cumbersome and lack precision.
Innovation Solution
A device utilizing a tower crane or gantry system with digitally controlled winches and cables, where the verticality of the suspension cable is maintained by adjusting the carriage and beam positions, allowing for precise control of the extrusion head's position in three dimensions, enabling the deposition of pasty material layer by layer with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rigid scaffolding or gantry systems are used for large-scale 3D printing, then structural stability is improved, but positioning precision in the vertical direction deteriorates
Solution Approach 1:
The patent replaces conventional rigid mechanical scaffolding or gantry systems with a cable-suspended system. Instead of using heavy rigid beams and supports, the invention uses flexible cables tensioned between anchor points to suspend the extrusion head, enabling precise positioning through cable length adjustment while maintaining structural stability through proper cable tensioning and anchoring.
Solution Approach 2:
The invention changes the fundamental parameter of structural support from rigid mechanical connections to flexible cable tensions. By controlling cable lengths and tensions, the system achieves both structural stability and positioning precision, resolving the contradiction between rigid support requirements and precise vertical positioning.
2Manufacturing precision
If thin layers are deposited to achieve high quality finished objects, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The cable-suspended system enables dynamic adjustment of the extrusion head position and allows for optimized deposition strategies. The system can rapidly reposition between layers and adjust cable tensions to maintain precision during faster deposition processes, reducing the time penalty associated with high-precision thin layer deposition.
3Length of stationary object
If large-scale structures are constructed beyond 5m dimensions, then application scope is expanded, but positioning precision deteriorates due to device rigidity requirements
Solution Approach 1:
The invention transitions from a traditional ground-based or scaffold-supported horizontal positioning system to a cable-suspended system where the extrusion head is positioned in three dimensions through cable length adjustments. This dimensional change allows precise control over large distances by utilizing vertical cable tension as a primary positioning mechanism, overcoming the rigidity limitations of conventional large-scale systems.
Data Source
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AI summary
The invention relates to a device for producing industrial elements of very large dimensions (1) and more specifically buildings. The device carries out spatial positioning by cables (L1, L2, L3) and uses an extrusion head (2a) to continuously deposit a pasty material in thin layers, for example a mortar comprising either a cementing substance, or thermoplastic, thermohardenable or cross-linkable compounds. The invention also relates to a method for producing three-dimensional structures using said device.