Shuttering Profile Segmentation for Prefabricated Concrete Formwork
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Solution Overview
Problem
Existing methods for producing formwork for precast concrete elements are inefficient, requiring extensive manual handling of shims and leading to significant time delays, especially in automated production lines, due to the need for multiple shuttering profiles of different lengths and manual handling of shims during production and demolding.
Innovation Solution
The method involves arranging at least two shuttering profiles one behind the other, with their combined length being less than the required side length, and using more profiles than necessary sides, allowing for standardized lengths and minimizing the need for shims, while a program-controlled robot facilitates faster and more efficient shuttering and demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If shims are used to fill gaps between shuttering profiles, then the formwork can accommodate standard length profiles, but the production time increases due to manual handling of shims during assembly and demolding
Solution Approach 1:
The invention divides the shuttering profile into multiple standardized segments that can be combined in different configurations. Instead of using one long profile with shims, the side is formed by multiple shorter standardized profiles arranged end-to-end, eliminating the need for shims and manual adjustment while maintaining adaptability to different side lengths
Solution Approach 2:
The invention creates a universal shuttering system where a limited set of standardized profiles can serve multiple functions and accommodate various side lengths through different combinations. The same standardized profiles can be used across different formwork configurations, eliminating the need for custom-length profiles and shims
2Manufacturing precision
If multiple different lengths of shuttering profiles are used, then the formwork can precisely match the precast concrete element dimensions, but the device complexity and inventory requirements increase
Solution Approach 1:
The invention uses homogeneous standardized profiles with uniform dimensions and connection features throughout the system. All profiles follow the same design standards, making them interchangeable and simplifying inventory management, while still achieving precise dimensions through standardized combination patterns
Solution Approach 2:
By segmenting the formwork into multiple standardized profile units, the invention achieves precise overall dimensions through the cumulative effect of standardized segments rather than requiring custom-length individual profiles, thereby reducing device complexity
3Ease of manufacture
If manual handling of shims is required during demolding, then the formwork can be assembled with standard profiles, but the overall production cycle time increases significantly
Solution Approach 1:
The invention extracts and eliminates the shim component entirely from the formwork system. By designing the shuttering profiles to connect directly end-to-end without gaps, the need for shims is removed, thereby eliminating the manual handling time during both assembly and demolding operations
Solution Approach 2:
The standardized profiles are pre-designed with connection features that enable direct end-to-end assembly without requiring intermediate shims. This preliminary design consideration eliminates the need for manual shim insertion and subsequent removal, streamlining both assembly and demolding processes
Data Source
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AI summary
The method involves selecting top end profiles (10) to be positioned according to a desired value of a length. The length is determined based on a geometric data set for a rectangular prefabricated concrete element to be manufactured. Two of the profiles, which are arranged successively in longitudinal direction, are selected for forming a side of a formwork (11) for the element. Sum of longitudinal extensions of the profiles is smaller than length (L) of the side of the formwork.