3D Printing Material Delivery System with Torque-Based Consistency Control
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Solution Overview
Problem
Traditional construction methods for structures like dwellings are time-consuming and require multiple skills and trades, extending the construction period significantly, which is undesirable for rapid construction needs.
Innovation Solution
A construction system utilizing additive manufacturing techniques, specifically 3D printing, with a printing assembly and material delivery system that includes a mixing unit with a controller to adjust the extrudable building material's consistency by measuring torque and adding water or dry ingredients accordingly, allowing for the rapid deposition of extrudable building materials on a foundation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional construction methods are used, then multiple skills and trades can be utilized, but the construction period is significantly extended
Solution Approach 1:
The patent changes the physical state and delivery parameters of building materials by developing extrudable materials with specific rheological properties that allow them to be pumped and deposited in controlled layers, enabling continuous construction operations that dramatically reduce construction time compared to traditional methods
Solution Approach 2:
The construction system enables continuous deposition of building materials layer by layer without interruption, allowing the printing head to continuously build structures 24/7 without the downtime inherent in traditional construction methods that require sequential manual operations
2Productivity
If additive manufacturing is used for rapid construction, then construction time is reduced, but material consistency control becomes critical
Solution Approach 1:
The system incorporates feedback mechanisms through torque sensors on the agitator motor that continuously monitor material viscosity and automatically adjust water addition rates to maintain consistent material properties, ensuring precise control during rapid construction operations
Solution Approach 2:
The mixing system serves multiple functions: it not only mixes dry ingredients and water but also acts as a viscosity control system with automated feedback, a material delivery pump, and a consistency monitoring device, all integrated into one multi-functional unit that maintains precision during high-speed operation
3Productivity
If automated material adjustment is implemented, then construction efficiency increases, but system complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated systems: the water tank, hopper, agitator, and control system are merged into a unified material delivery and mixing system that automatically manages material preparation and delivery, reducing the need for separate manual operations while maintaining manageable system 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
This approach enables the construction of structures in a fraction of the time associated with traditional methods, facilitating quicker and more economical construction of structures like personal dwellings by controlling the material's consistency and deposition process.
Implementation Method 1
The mixing unit includes an agitator that is configured to mix the water and the dry ingredients together to form the extrudable building material
Implementation Method 2
The controller is configured to: measure a load imparted to the agitator by the extrudable building material
Implementation Method 3
a printing assembly configured to deposit an extrudable building material to form a structure
Implementation Method 4
The material delivery system includes a water tank and a hopper configured to hold dry ingredients of the extrudable building material therein
Data Source
AI summary
Material delivery systems as well as systems and methods relating thereto are disclosed. In an embodiment, the material delivery system includes a tank to hold water therein. In addition, the material delivery system includes a hopper to hold dry ingredients of the extrudable building material therein. Further, the material delivery system includes a mixing unit to receive water from the tank and dry ingredients from the hopper. The mixing unit includes an agitator to mix the water and the dry ingredients together to form the extrudable building material. Still further, the material delivery system includes a controller coupled to the agitator that is to: measure a load imparted to the agitator by the extrudable building material, add additional water to the mixing unit when the load is above a first threshold, and add additional dry ingredients to the mixing unit when the load is below a second threshold.