3D Printing Mortar Viscosity Control via Coriolis Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3-D printing methods for concrete and mortar elements face issues with weak bonding strengths between layers due to the use of quick-setting cements and additives, leading to non-monolithic materials with low load-bearing capacity, and lack of real-time quality control for mixing ratios.
Innovation Solution
A system that measures the viscosity, density, and flow of wet mortar online using a Coriolis-type sensor, allowing for real-time adjustment of the mixing ratio and ensuring stable properties, enabling 'wet-on-wet' deposition with improved adhesion and bonding strength, and using thixotropic mortars to achieve mechanical properties comparable to conventional cast concrete.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If quick-setting cements and additives are used to increase yield stress, then the mechanical resistance of deposited layers is improved, but the bonding strength between layers deteriorates
Solution Approach 1:
The patent applies preliminary action by measuring the viscosity and density of wet mortar online before deposition, allowing real-time adjustment of mixing ratios to optimize material properties for both mechanical resistance and layer bonding, preventing the need for quick-setting cements that compromise bonding
Solution Approach 2:
The patent implements feedback control through online measurement of viscosity and density using sensors, with the controller adjusting mixing ratios based on measured values to maintain optimal material properties, ensuring both adequate mechanical resistance and strong interlayer bonding without requiring compromising additives
2Strength
If quick-setting cements and additives are used, then the adhesion between layers is improved, but the material becomes non-monolithic with low load bearing capacity
Solution Approach 1:
The system performs preliminary measurement of viscosity and density before deposition, enabling real-time optimization of mixing ratios to achieve proper material consistency that ensures both adhesion and monolithic structure without compromising either property
Solution Approach 2:
The patent changes the mixing ratio parameter in real-time based on online viscosity and density measurements, optimizing material properties to achieve both adequate adhesion and monolithic structure, avoiding the non-monolithic results caused by additives
3Manufacturing precision
If online measurement of viscosity and density is implemented, then quality control is improved, but device complexity increases
Solution Approach 1:
The Coriolis-type sensor performs multiple functions simultaneously by measuring both viscosity and density of the wet mortar in a single device, reducing overall system complexity while maintaining comprehensive quality control capabilities
Solution Approach 2:
The system implements self-service through automated online measurement and controller-based adjustment of mixing ratios, eliminating the need for manual quality checks and adjustments, thereby improving precision without proportionally increasing operational complexity
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 system ensures robust and high-quality 3-D printed elements with improved adhesion and bonding strength between layers, achieving mechanical properties comparable to conventional cast concrete, while avoiding issues related to additive use and ensuring real-time quality control.
Implementation Method 1
a Coriolis-type sensor, which is able to measure simultaneously the density, the flow, the viscosity and the temperature of the wet mortar
Implementation Method 2
Thanks to their thixotropic properties, the mortars used have a low viscosity at higher shear rates so that they can be easily pumped and conveyed throughout the system
Data Source
Figure 1
AI summary
The invention relates to a system for implementing a manufacturing method of construction elements (10) comprising hydraulic binder and aggregates, said system comprising: - a mixing device (40) adapted to mix a dry mortar composition comprising hydraulic binders and aggregates with water, to form a wet mortar, - an outlet (20), - a pumping device (50) adapted to pump and convey said wet mortar towards said outlet (20), and at least one sensor (30) adapted to measure on-line at least two physical properties of said wet mortar on its way from said mixing device to said outlet, said physical properties including viscosity and at least one of flow and density.