GPS-Coordinated Self-Climbing Formwork for High-Rise Automation
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Solution Overview
Problem
The construction of high-rise building structures remains labor-intensive and inefficient, with significant manpower required for forming, rebar assembly, and geomatics precision, leading to productivity losses and increased safety risks due to the reliance on hydraulic climbing systems and manual alignment processes.
Innovation Solution
A device integrating a self-climbing mechanism, concrete application mechanism, rebar arrangement mechanism, and levelling and dampening system, all GPS-controlled for precise coordination and automation, utilizing robots for additive manufacturing and rebar placement, and a hydro-mechanical levelling system for stabilization and vibration mitigation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydraulic climbing systems are used for construction, then the structure can be built vertically, but labor intensity remains high and productivity is reduced
Solution Approach 1:
The climbing formwork system is equipped with its own climbing mechanism that enables it to ascend automatically along the building structure without requiring external crane assistance or manual intervention for repositioning. The system climbs by anchoring to the previously constructed concrete sections and using hydraulic or mechanical forces to elevate itself, thereby serving its own positioning needs and significantly reducing labor requirements.
Solution Approach 2:
The patent replaces traditional mechanical crane-based lifting systems with an integrated self-climbing mechanism that uses hydraulic actuators and mechanical anchoring systems built into the formwork itself. This substitution eliminates the need for separate heavy lifting equipment and manual operation, automating the vertical movement process.
2Measurement precision
If manual alignment and plumbing processes are used, then flexibility is maintained, but geomatics precision is insufficient and time consumption increases
Solution Approach 1:
The patent replaces manual alignment and plumbing operations with automated laser-based measurement and control systems. These systems use optical sensors, lasers, and digital processing to automatically establish precise horizontal and vertical references, eliminating the need for manual bubble levels, theodolites, and other traditional surveying tools, thereby achieving superior precision and speed.
Solution Approach 2:
The system incorporates real-time feedback mechanisms where sensors continuously monitor the position and alignment of the climbing formwork, and the control system automatically adjusts positioning based on this feedback to maintain precise geomatics accuracy throughout the climbing process and concrete pouring operation.
3Manufacturing precision
If formwork systems with many metallic and wooden components are used, then adaptability is achieved, but manufacturing precision becomes difficult due to varying tolerance ranges
Solution Approach 1:
The patent specifies controlled parameter ranges for all formwork components, including dimensional tolerances, material properties, and assembly clearances. By establishing and maintaining these parameters within defined limits during manufacturing and assembly, the system achieves consistent manufacturing precision despite the complexity of having multiple component types with different properties.
Solution Approach 2:
The formwork system is divided into standardized modular segments that can be manufactured with controlled tolerances and then assembled through precision-machined connection interfaces. This segmentation allows each component to be manufactured independently with tight tolerances, and the cumulative assembly precision is maintained through precise mating surfaces and alignment features.
4Manufacturing precision
If intensive labor is used for alignment and plumbing, then formwork accuracy is improved, but productivity decreases and safety risks increase
Solution Approach 1:
The patent replaces labor-intensive manual alignment and plumbing operations with automated laser-based measurement systems and computer-controlled positioning mechanisms. These systems rapidly establish precise references and automatically guide the formwork positioning, achieving both high accuracy and fast operation speeds simultaneously, thereby eliminating the trade-off between precision and productivity.
Solution Approach 2:
The climbing formwork system performs its own alignment and positioning operations automatically through integrated sensors and control systems, eliminating the need for separate manual alignment crews and procedures. This self-service capability maintains high precision while significantly reducing the time required for these operations.
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
The device significantly reduces labor intensity, enhances geomatics precision, and increases productivity by automating the construction process, allowing for more accurate and efficient construction of high-rise structures with reduced downtime and costs.
Implementation Method 1
The self-climbing mechanism and the concrete application mechanism are separately or commonly GPS-controlled by said GPS-system, so that the climbing movement of the self-climbing mechanism and the spatial progress with respect to an additive manufacturing of the concrete application mechanism are coordinated
Implementation Method 2
a levelling and dampening system, wherein said concrete application mechanism is configured to apply concrete by way of additive manufacturing
Implementation Method 3
a levelling and dampening system for stabilization and vibration mitigation
Data Source
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AI summary
The present invention relates to a device and a method for the construction of high rising building structures, which use a GPS-system (14) to coordinate the climbing process of a self-climbing mechanism (2) with construction operations, which construction operations may be performed by automated concrete application mechanisms (10) and automated rebar arrangement mechanisms (12).