Sensor Unit for Lost Formwork Pressure Monitoring
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Solution Overview
Problem
The existing methods for concrete construction in lost formwork are limited by the need to maintain a low rate of concrete pouring to avoid exceeding the maximum concrete pressure, which slows down the process and may not fill the void completely, lacking real-time pressure monitoring to ensure safety and efficiency.
Innovation Solution
A sensor unit is inserted into the formwork wall to measure lateral pressure, comprising a pressure chamber, pressure transducer, control unit, and an actuating device with an expansion member for secure and easy installation, allowing for real-time pressure monitoring during concrete pouring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rate of concrete pouring is increased to improve productivity, then the pouring speed increases, but the lateral concrete pressure exceeds the maximum design pressure of the formwork walls
Solution Approach 1:
The patent implements a feedback mechanism by installing a pressure sensor in the formwork wall that continuously monitors lateral concrete pressure and transmits this data to a control device. The control device receives pressure data, compares it against the maximum design pressure, and provides real-time feedback to adjust the pouring rate accordingly, enabling safe operation at higher pouring speeds without exceeding pressure limits
Solution Approach 2:
The patent replaces the traditional mechanical approach of manually controlling pouring speed based on experience and conservative estimates with an automated sensor-based control system. The pressure sensor, control device, and communication system substitute for manual mechanical control, enabling precise, real-time monitoring and adjustment of pouring parameters based on actual pressure conditions
2Reliability
If the rate of concrete pouring is decreased to maintain safety within maximum pressure limits, then the lateral pressure remains acceptable, but the pouring process becomes slower and time-consuming
Solution Approach 1:
The feedback mechanism allows the system to operate at higher pouring speeds by continuously monitoring pressure and adjusting the rate in real-time. Instead of being constrained by conservative time limits, the system can optimize pouring speed based on actual pressure conditions, reducing overall pouring time while maintaining safety
Solution Approach 2:
The pressure sensor is installed in advance during formwork assembly, and the control system is configured before pouring begins. This preliminary setup enables real-time pressure monitoring and automated rate adjustment to start immediately, eliminating the need for slow, conservative pouring and reducing overall construction time
3Device complexity
If no pressure monitoring is implemented to simplify the system, then the formwork construction remains simple, but the actual concrete pressure is unknown and cannot be optimized
Solution Approach 1:
The patent replaces complex mechanical pressure measurement systems with a simplified sensor-based electronic system. The pressure sensor, control device, and communication components provide accurate real-time pressure data with minimal complexity, enabling informed decision-making about pouring rates without overwhelming system complexity
Solution Approach 2:
The patent introduces a pressure sensor as an intermediary element between the concrete and the control system. This sensor acts as a mediator that converts physical pressure into electrical signals, which are then processed by the control device and communicated to operators, providing necessary information without directly complicating the overall system
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
Enables faster and safer concrete pouring by providing real-time pressure data, allowing for optimal pouring rates while maintaining pressure within design limits, thus saving time and ensuring complete filling of the void.
Implementation Method 1
a pressure transducer connected to the pressure chamber
Implementation Method 2
an expansion member and an actuating device adapted to actuate the expansion member, wherein the expansion member, in an actuated state, is adapted to fasten the sensor unit in the opening of the formwork wall
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The present invention provides a sensor unit (1) insertable in an opening (2) of a formwork wall (3) of a lost formwork (4) for building material (M) construction, comprising an arrangement (16) for fastening and releasing the sensor unit (1) in the opening (2) of the formwork wall (3), comprising an expansion member (18) and an actuating device (20) adapted to actuate the expansion member (18), wherein the expansion member (18), in the actuated state (S1), is adapted to fasten the sensor unit (1) in the opening (2) of the formwork wall (3), and wherein the expansion member (18), in a non-actuated state (S2), is adapted to release the sensor unit (1) from its fastening in the opening (2) of the formwork wall (3). The present invention further provides a lost formwork for concrete construction comprising the sensor unit according to the invention.