Automated Concrete Shell Construction via Robotic Nozzle and Crane
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Solution Overview
Problem
Existing methods for manufacturing self-bearing shell structures, such as concrete domes, rely heavily on manual application of concrete, which results in inconsistent quality and thickness due to operator skill variability, and inflatable forms often lift off the ground during inflation, complicating the construction process.
Innovation Solution
A computer-controlled system comprising a material supply unit with a manipulation arm and nozzle suspended from a traverse crane, allowing precise concrete application according to a CAM-pattern, and a flange form to prevent inflatable forms from lifting, enabling accurate and efficient construction of large-scale shell structures with adjustable thickness and material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual application of concrete is used, then operator flexibility is maintained, but quality consistency and thickness precision deteriorate due to operator skill variability
Solution Approach 1:
The patent replaces manual mechanical application with a computer-controlled robotic system that uses sensors to detect form geometry and automatically adjusts application parameters. This substitution eliminates operator skill variability while maintaining flexibility through programmable control, directly resolving the contradiction between precision and device complexity.
Solution Approach 2:
The system dynamically changes application parameters such as material flow rate, nozzle position, and application speed based on real-time sensor feedback and pre-stored form geometry data. This allows the system to adapt to different form shapes and thickness requirements automatically, achieving high precision without requiring complex manual intervention.
2Reliability
If more concrete is applied to ensure adequate coverage, then quality assurance improves, but material waste increases
Solution Approach 1:
The system incorporates sensors that continuously monitor the application process and provide feedback to the control system. This feedback mechanism allows real-time adjustment of material application rates based on actual form geometry and previously applied material, ensuring adequate coverage without over-application, thus resolving the contradiction between quality assurance and material waste.
Solution Approach 2:
Instead of applying excessive concrete uniformly across all surfaces, the system applies material selectively based on detected form geometry and required thickness specifications. This partial action approach ensures adequate coverage only where needed, eliminating unnecessary material waste while maintaining quality assurance.
3Adaptability or versatility
If inflatable forms are used to create shell structures, then structural complexity and shape versatility improve, but form stability deteriorates due to lifting off ground during inflation
Solution Approach 1:
The patent employs anchoring mechanisms that provide counteracting forces to prevent the inflatable form from lifting off the ground during inflation. These anchoring systems balance the internal pressure forces, maintaining form stability while allowing the form to achieve its intended complex shape, thus resolving the contradiction between shape versatility and form stability.
4Manufacturing precision
If computer-controlled material application is implemented, then material distribution precision and thickness control improve, but system complexity and initial setup requirements increase
Solution Approach 1:
The system incorporates pre-stored geometry data of the form in its memory before the application process begins. This preliminary preparation allows the control system to automatically plan and execute the material application path and parameters without requiring complex real-time calculations or manual programming during operation, reducing setup complexity while maintaining high precision.
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 consistent and precise application of concrete, reducing material waste and ensuring accurate structure thickness, enhancing the quality and floating characteristics of structures like sea farms and boat hulls, while allowing for flexible production and efficient use of space.
Implementation Method 1
a material supply system, comprising a material tank and a material pump and furthermore a material dispensing nozzle
Implementation Method 2
covering forms with a tempering concrete... the inside of an inflatable form is covered with concrete
Data Source
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AI summary
System for construction of large-scale self-bearing shell structures in a setting material. The system comprises a self-contained unit with a material supply system, a material tank and a pump connected to said supply system. It also has a material dispensing nozzle and a manipulation arm. The supply system is adapted to feed the material to the nozzle. Computer-controlled actuators control the manipulation arm and dispensing of material. A traverse crane carries said unit, which is adapted to be computer controlled according to a CAM-pattern. The nozzle can be moved in an arbitrary path within a predetermined operation section, as well as be arranged for dispensing material in substantially any arbitrary direction, by means of said dispensing nozzle and manipulation arm. Components are suspended from the traverse crane and the tank is suspended from the traverse crane or adapted to move with the bogie of the same.