Slip Form Control for Variable Material Setting Rates
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Solution Overview
Problem
Conventional slip forming methods face issues with non-uniform setting rates of materials, leading to deformations and structural problems like bulging or cracks in building structures, due to a mismatch between the rising rate of the slip form and the setting rate of the material.
Innovation Solution
A slip form system that dynamically controls the movement of the slip form based on real-time information about the setting rate of the material mixture, using sensors to adjust speed, position, and angle, allowing for continuous formation of building structures with improved surface finish and reduced production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a steady rising rate is set for the slip form movement, then the slip form can continuously move along the building plane, but deformations such as bulging or cracks occur when the setting rate of material is non-uniform
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed steady rising rate to a variable rising rate that dynamically adapts to the material's setting rate. The controller continuously adjusts the actuator's movement speed based on real-time feedback from sensors monitoring material setting characteristics, allowing the slip form to move faster when material sets quickly and slower when material sets slowly, thereby preventing deformations while maintaining continuous operation.
Solution Approach 2:
The patent implements feedback control by using sensors to detect the setting rate of the material mixture and feeding this information back to the controller. The controller then adjusts the slip form's rising rate accordingly, creating a closed-loop system that automatically compensates for variations in material setting behavior, thus preventing bulging and cracks while optimizing production efficiency.
2Productivity
If the slip form moves faster to increase production rate, then productivity increases, but deformations and structural problems occur due to mismatch with material setting rate
Solution Approach 1:
The system dynamically adjusts the rising rate based on real-time material setting conditions, enabling the slip form to operate at optimal speeds that maximize productivity without compromising structural integrity. When material sets rapidly, the system increases speed to boost production; when setting is slow, it reduces speed to prevent deformations, thus achieving both high productivity and reliable structural outcomes.
Solution Approach 2:
Through continuous monitoring of material setting rate and feedback-controlled adjustment of the slip form's movement speed, the system ensures that productivity enhancements do not come at the cost of structural reliability. The feedback mechanism prevents deformations by automatically reducing speed when material conditions indicate vulnerability, while allowing speed increases when material strength develops sufficiently.
3Strength
If traditional formwork is used to support the slip form, then structural stability is maintained, but costs increase due to large proportion of total costs
Solution Approach 1:
The patent replaces the traditional mechanical formwork support system with a dynamically controlled actuator system. Instead of relying on heavy formwork structures for support, the invention uses an actuator driven by a controller that responds to material setting feedback, substituting mechanical support with an intelligent control-based support mechanism that reduces material costs while maintaining structural stability.
Solution Approach 2:
The system changes the control parameter from fixed mechanical support to dynamically adjustable movement parameters based on material setting rate. By controlling the rising rate as a variable parameter rather than relying on static formwork, the system achieves structural stability with reduced formwork requirements, thereby lowering the overall cost of the forming system.
Data Source
AI summary
Embodiments of the present invention relate to a slip form system for forming a building structure comprising an inlet for receiving a flow of a material mixture comprising a setting material and an accelerant, a slip form, a support supporting the slip form and an actuator for continuously moving the slip form supported by the support. The slip form system further comprises a controller in communication with the actuator and configured to dynamically control the moving slip form, wherein the slip form system is configured such that when a flow of material mixture is received within the slip form, the controller uses information relating to a setting rate of the material mixture to control movement of the slip form to continuously form the building structure.