Cement Extrusion Control With Sensor-Guided Additive Dosing
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Solution Overview
Problem
Existing systems for extruding cementitious materials in additive manufacturing lack precise control over the properties of the printing composition, leading to inefficiencies and suboptimal quality of the printed material.
Innovation Solution
A system and method that incorporates temperature and pressure sensors in a closed loop with a control unit to adjust the amount of additives in the cementitious material, using a mixing chamber and extruder with a motor-driven mixer, ensuring homogenous mixing and controlled extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If temperature and pressure sensors are integrated with a control unit to adjust additive amounts in real-time, then the manufacturing precision and quality of the printed material are improved, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The system integrates temperature and pressure sensors that continuously monitor the printing composition properties and feed this data back to a control unit. The control unit automatically adjusts the amount of additives in real-time based on the sensor readings, creating a closed-loop feedback system that maintains precise control over material properties without requiring manual intervention.
Solution Approach 2:
The invention replaces manual or mechanical adjustment methods with automated electronic control. Instead of physically adjusting additive amounts through mechanical means, the system uses electronic sensors and a control unit to automatically regulate the composition, substituting mechanical adjustment with intelligent automated control.
2Manufacturing precision
If a motor-driven mixer is used to ensure homogenous mixing of cementitious material and additives, then the manufacturing precision is improved, but the device complexity and energy consumption increase
Solution Approach 1:
The motor-driven mixer is designed with variable speed control that allows the mixing process to be dynamically adjusted. The mixer can operate at different speeds depending on the specific mixing requirements - higher speeds for initial mixing and lower speeds for final homogenization - optimizing energy consumption while maintaining mixing quality.
Solution Approach 2:
The mixing process is designed to be continuous rather than intermittent, with the motor-driven mixer operating continuously throughout the material preparation phase. This continuous action ensures uniform mixing without interruption, preventing segregation and ensuring homogenous distribution of additives throughout the cementitious material.
3Productivity
If the system allows faster setting of the printing composition through controlled additives, then the productivity is improved, but the manufacturing precision may be compromised due to reduced working time
Solution Approach 1:
The system controls the setting speed by precisely adjusting the amount and type of additives introduced into the cementitious material. By changing the chemical composition parameters - specifically the ratio and quantity of setting accelerators or retarders - the system can optimize both the setting speed and the final material quality, allowing faster setting without compromising structural integrity.
Solution Approach 2:
The additive distribution is optimized to create local variations in setting characteristics. The motor-driven mixer ensures uniform distribution of additives throughout the material, creating consistent local properties that allow controlled setting throughout the entire printed structure, maintaining quality even with accelerated setting times.
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
Enhances the quality and efficiency of the printing process by allowing faster setting of the printing composition, enabling precise control over the properties for improved adhesion and structural integrity of the printed layers.
Implementation Method 1
a mixing chamber (10) comprising a cementitious material inlet (11) connected to said at least one pump of cementitious material via a cementitious material supply line (32), and an inlet of additive for cementitious material (12) connected to said at least one pump of additive for cementitious material via a supply line of additive for cementitious material (33); said mixing chamber (10) being configured to mix the cementitious material with the additive for cementitious material, thereby forming a printing composition
Implementation Method 2
an extruder (20) for extruding at least one layer of the printing composition through an outlet (21) thereof
Implementation Method 3
The extruder (20) comprises at least one temperature sensor, and in that the mixing chamber (10) comprises at least one pressure sensor at the cementitious material inlet (11), each sensor being operatively connected in closed loop to the control unit
Implementation Method 4
The extruder (20) comprises at least one temperature sensor, and in that the mixing chamber (10) comprises at least one pressure sensor at the cementitious material inlet (11), each sensor being operatively connected in closed loop to the control unit
Implementation Method 5
each sensor being operatively connected in closed loop to the control unit, which is configured to adjust the amount of additive for cementitious material in the printing composition based on the temperature and pressure measured by said sensors
Data Source
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AI summary
It is disclosed a system for extruding cementitious material comprising: - at least one pump (30, 34) of cementitious material; - at least one pump (31) of additive for cementitious material; - a mixing chamber (10) comprising a cementitious material inlet (11) and an inlet (12) of additive for cementitious material; and being configured to mix the cementitious material with the additive for cementitious material forming a printing composition; - an extruder (20) for extruding at least one layer of the printing composition; - a control unit; wherein the extruder (20) comprises at least one temperature sensor (T1), and the mixing chamber (10) comprises at least one pressure sensor (P1) at the cementitious material inlet (11), each sensor (T1, P1) being operatively connected to the control unit, which is configured to adjust the amount of additive for cementitious material in the printing composition. It is also disclosed a method for extruding cementitious material and a system for additive manufacturing of a cementitious material-based structure.