RU2794010C1 - Construction 3d printing complex - Google Patents

Abstract

FIELD: construction industry.

SUBSTANCE: construction 3D printing complex includes a building mixture preparation station connected in series, containing a water supply unit and a receiving cavity connected by a screw conveyor to a mixing chamber, a pumping station and a construction 3D printer. The complex contains at least one video camera, a video signal display device, a light and sound signalling device and a controller that is configured to transmit control signals to each device of the complex and receive feedback signals from them. To work with the use of dry ready mixes, the complex contains a capacitive hopper connected by means of a screw feeder to the receiving cavity of the mixture preparation station.

EFFECT: increased reliability of equipment included in the complex; reduction in energy consumption; speeding up the construction process.

3 cl, 7 dwg

Description

Technical field

The invention relates to the construction industry. The complex is intended for the erection of structures of buildings and structures, their elements, including fixed formwork, small architectural forms, etc. directly on the construction site. on an electronic 3D geometric model, by laying the material for additive building production, layer by layer.

State of the art

A known system for preparing and supplying material for a construction 3D printer (RF patent for invention No. 2767464, class IPC B29C 67/04, E04G 21/02, publ. 03/17/2022), containing a housing, inside which there are two cavities: a mixing cavity and the feed cavity, interconnected by a channel for supplying the finished mixture, a mixing shaft is installed in the mixing cavity, a feed shaft is installed in the feed cavity, while the mixing shaft is rotatable due to its own drive and is a cylinder with two functional elements installed on it: mixing elements and a supply element, the supply shaft is rotatable due to its own drive and is a rotor of a gerotor pair, and the axes of the mixing shaft and the supply shaft are mutually perpendicular, while a cyclone for supplying a dry mixture in powder form is connected to the mixing cavity, which is connected with a dry mixture supply channel, as well as a liquid supply channel, a replaceable nozzle with its own drive is installed at the exit from the supply cavity.

A construction 3D printer is known (RF patent for the invention No. 2753324, class IPC E04B 1/16, B33Y 30/00, published on 08/13/2021), containing supports, a printing unit suspended on supports using cables, winches for controlling the lengths of cables and a mortar preparation and supply device, wherein the printing unit comprises a printing device with at least two dies, each of which is mounted on its own linear movement mechanism.

A mobile construction 3D printer is known (patent for invention No. 2636980, published on November 29, 2017), which includes a chassis containing a platform with an engine installed on it driven by a propulsor in the form of wheels; lifting mechanism along the Z axis; a print head comprising an extruder and a motor driven extruder mixture supply mechanism; hardware part with a power supply, a positioning device and a CNC control unit. Chassis platform additionally contains a cabin with an operator's workplace and chassis controls located inside it; CNC linkage module, containing CNC linkage with installed mechanisms for moving the print head along the X, Y, Z axes, as well as motors and drives for each X, Y, Z axis, CNC linkage holder, made with the possibility of moving it by means of a lifting mechanism along CNC linkage module, mechanical fastening of the CNC linkage module with vertical and horizontal adjustment mechanisms located on it, providing a given deviation of the CNC linkage module and the CNC linkage itself vertically and horizontally, respectively; a device for preparing and supplying the mixture to the print head; the hardware part additionally contains a control unit for the preparation and supply of the mixture.

The disadvantage of the known 3D printing systems is the inconsistency of the operation of the system elements, which negatively affects the reliability, efficiency, printing speed and quality of the manufactured building structures.

Brief description of drawings and other materials

In FIG. 1 shows a block diagram of the interaction of the elements of the construction 3D printing complex.

In FIG. 2 shows a diagram of the loading option for the finished dry building mix.

In FIG. 3-7 photos of the stages of the complex operation are presented: installation of a 3D printer; the beginning of 3D printing at home; exit to the windows; internal cavity of the building; emulation of the model on the operator's console.

The following designations are accepted in the figures: 1 - complex controller, 2 - station for preparing a building mixture (concrete or mortar) for printing, 3 - pumping station, 4 - construction 3D printer, 5 - video signal display device, 6 - video camera, 7 - light - sound signaling device, 8 - mix components for batching, 9 - container with dry mix, 10 - capacitive hopper, 11 - screw feeder, GSP - ready mix for printing, ~ - control and feedback signals.

Disclosure of invention

The technical result, which is achieved with the help of the proposed invention, is to increase the reliability and efficiency of the equipment included in the complex, which reduces the operating costs for maintenance and repair of the complex. The complex also allows to reduce energy consumption by optimizing the operation of the equipment; expand the functionality and modernization potential due to the possibility of completing the complex with additional devices and systems. Also, the claimed complex makes it possible to speed up construction, minimize defects in the production of work, and reduce the number of maintenance personnel of the complex.

The specified technical result is achieved by the fact that the construction 3D printing complex includes the following connected in series: a building mixture preparation station, a pumping station and a construction 3D printer, and the complex also contains at least one video camera, a video signal display device, a light and sound signaling device and a controller that is configured to transmit control signals to each device of the complex and receive feedback signals from them.

The building mixture preparation station contains a water supply unit and a receiving cavity connected by a screw conveyor to a mixing chamber.

The pumping station contains a mixing chamber, a gerotor pump and a mortar sleeve.

The video display device can be made in the form of a monitor, tablet, laptop, mobile phone.

To work with the use of dry ready mixes, the complex may additionally contain a capacitive hopper connected by means of a screw feeder to the receiving cavity of the mixture preparation station.

The declared complex is distinguished by the presence of a controller that provides control of all elements of the complex, as well as a station for the preparation and automatic supply of concrete or mortar for printing on the print head (hopper) of a construction 3D printer. The claimed technical solution of the complex provides synchronization of the process of supplying the building mixture to the printer's print head, the process of printing the building structure becomes automated, which avoids additional labor costs, reduces the printing time of the structure and improves its quality characteristics.

Implementation of the invention

The construction 3D printing complex includes the following connected in series: a construction mixture preparation station 2, a pumping station 3 and a construction 3D printer 4, and the complex also contains at least one video camera 6, a video signal display device 5, a light and sound signaling device 7 and controller 1.

The controller 1 is configured to transmit control signals to each device of the complex and receive feedback signals from them.

Station 2 is designed for the preparation and automatic supply of concrete or mortar for printing using pump station 3 to the print head (hopper) of a construction 3D printer 4. Station 2 for preparing a building mix contains a water supply unit and a receiving cavity connected by a screw conveyor to a mixing chamber.

Pumping station 3 contains a mixing chamber, a gerotor pump and a mortar sleeve.

The display device 5 video signal can be made in the form of a monitor, tablet, laptop, mobile phone.

To work with the use of dry ready mixes, the complex may additionally contain a capacitive hopper 10 connected by means of a screw feeder 11 to the receiving cavity of the mixture preparation station 2.

The construction 3D printing complex works as follows.

The station 2 for the preparation of building mixture can operate in the power mode, both on ready-made dry mixtures of factory production, and on individual components of mixtures with the possibility of mixing.

Work on dry ready mixes (see Fig. 2).

Ready mixtures are delivered from the factory in rigid containers 9 or in soft containers (for example, big bags), the contents of which are poured into a 10 capacitive hopper (silo).

From the capacitive hopper 10, through the screw feeder 11, the mixture enters the receiving cavity of the station 2, from which it is moved by a screw conveyor to the mixing chamber, where it is closed with water in the required amount. The amount of the mixture delivered to the station 2 is consistent with the productivity of the construction 3D printer 4 in terms of mortar/concrete.

Then, the closed mixture enters the mixing chamber of the pumping station 3, from where it is fed through the solution hose to the print head (hopper) of the printer 4.

Work on the components of the mixture.

The components of the mixture are fed into the receiving cavity of station 2 individually, mechanized through screw feeders in the required proportions. In the receiving cavity of station 2, the components are mixed to a homogeneous composition of the mixture, which is moved by a screw conveyor into the mixing chamber. Further, the process continues, as in the case of station 2 operation on dry ready mixes.

The operation of the devices included in the complex is coordinated with each other at the hardware level, through an automatic system for monitoring the 3D printing process according to a distributed principle, and is easily scalable, both in hardware and functionality.

For example, the positioning speed of the construction 3D printer 4 along the X and Y axes can vary from 0 to 14.5 m/min (0...0.24 m/s).

Moreover, the productivity of concrete (mortar) also varies in the range from 0 to 0.696 m ³ per hour in proportion to the change in speed.

Station 2 for preparing concrete or mortar for 3D printing has a water supply unit for mixing a mixture of concrete or mortar components in an amount of 3-5 l/min with a control limit of ±5%.

The construction 3D printing complex is based on reliable software and hardware, which implies ease of maintenance and upgrades.

The complex allows to produce:

- correct launch and control of the state of the equipment of the complex in the current time mode;

- correct shutdown of the complex, including automatic washing of parts of the equipment in contact with mortar or concrete;

- setting the settings of the agreed modes of operation;

- video recording of the printing process and viewing of parameters, events, accident logs for 512 entries;

- light-sound signaling of emergency conditions;

- automatic control and accounting of personnel actions for the last 20 hours.

Automation of the technological process and linking all equipment into a single complex allows:

- increase the reliability of the equipment included in the complex;

- reduce energy consumption by optimizing equipment operation;

- reduce operating costs for maintenance and repair of the complex;

- speed up construction;

- reduce the amount of marriage in the production of works;

- reduce the number of service personnel of the complex;

- expand the functionality and modernization potential, depending on the configuration of the complex with additional systems and devices.

Implementation example

From April 4 to April 8, 2022, SMARTBUILD LLC tested the 3D printing construction complex (see photos of work stages in Fig. 3-7). As a result of the tests, the commission consisting of the employees of SMARTBUILD LLC: director, executive director and chief designer, recorded the following results.

1. The maximum positioning speed of the 3D printer along the X and Y axes was 14.3 m/min (0.234 m/s).

2. Positioning accuracy was no more than: +/- 1 mm.

3. The maximum productivity for concrete (mortar) was 0.689 m3/hour.

4. Water consumption has decreased by 35...40% compared to the traditional construction method.

5. Energy consumption decreased by 20...25% compared to the traditional construction method.

6. Maintenance costs of the complex are minimal (cleaning and washing of equipment) - 1...1.5 people/hour.

7. For the entire test cycle, not a single equipment failure was detected.

8. The speed of construction (3D printing) of a one-story building with an area of 100 m2 was 36 hours. Time savings amounted to 50...75% compared to the traditional construction method.

Thus, the claimed complex allows to increase the reliability of work, reduce operating costs and reduce energy consumption, as well as speed up construction, minimize defects in the production of work and reduce the number of maintenance personnel.

A comparative analysis of the claimed complex of building 3D printing shows that the totality of its essential features is unknown from the prior art and, therefore, corresponds to the condition of patentability "Novelty".

In the prior art, no features were identified that coincide with the distinctive features of the claimed complex and affect the achievement of the claimed technical result, therefore, the claimed invention meets the condition of patentability "Inventive step".

The given information confirms the possibility of using the claimed technical solution for the erection of building structures, structures and their elements directly on the construction site, and therefore complies with the patentability condition "Industrial applicability".

Claims (3)

1. Complex of building 3D printing, including connected in series: a building mixture preparation station containing a water supply unit and a receiving cavity connected by a screw conveyor to a mixing chamber, a pumping station and a building 3D printer, and the complex contains at least one video camera, a video signal display device, a light and sound signaling device and a controller that is configured to transmit control signals to each device of the complex and receive feedback signals from them, moreover, for operation using dry ready-made mixtures, the complex contains a capacitive hopper connected by means of a screw feeder to a receiving cavity mixing station. 2. The 3D printing complex according to claim 1, characterized in that the pumping station contains a mixing chamber, a gerotor pump and a mortar sleeve. 3. The 3D printing complex according to claim 1, characterized in that the video signal display device is made in the form of a monitor, tablet, laptop, mobile phone.

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