EP2714352B1 - Apparatus and process for producing components having at least one continuous property change - Google Patents

Description

The invention relates to a device for producing at least one concrete component, which is provided with at least one continuous or approximated continuous property change in at least one spatial direction. The invention further relates to a corresponding manufacturing method.

Out US 4,798,694 A. For example, a method for producing a composite material is known. In the process, various components are mixed, the mixture is placed in a rotary vessel and the rotary vessel is rotated at a controlled rate. On the general state of the art can still on the US 5,498,383 A , the US 2008/079185 A1 , the JP 2002 292611 A and the JP 2004 079332 A to get expelled. DE 196 08 754 A1 z. B. discloses a device for applying atomizable media by means of a rotating spray jet.

In the prior art concrete components made of homogeneous concrete mixtures (from ultra-high strength concrete to infrared light concrete) are known. Furthermore, sandwich-type and multi-layered concrete components are known, which have layers with abrupt, stepwise property change. The production of such concrete components usually takes place by casting, by wet spraying or dry spraying. Furthermore, multifunctional components are known, which are formed by a material mix (eg thermal insulation systems). It is also known to optimize components by changing the component geometry (structural lightweight). A disadvantage of the known components that they are usually insufficiently adapted to the actual structural and structural requirements, resulting in high material consumption, weight increase, high transport costs, waste of resources and high CO ₂ emissions.

In view of the above, it will be apparent to those skilled in the art from this disclosure that there is a need to solve or overcome the above-described problems or disadvantages. The invention addresses this need in the art as well as other needs which will become apparent to those skilled in the art from this disclosure.

The objects resulting from the above can be achieved in particular with the features of the independent claims. However, the invention is not limited to embodiments which eliminate all the problems or disadvantages of the prior art mentioned above. According to the invention, an apparatus is provided for producing at least one component, namely a concrete component. According to the invention, the device has at least two, preferably separate and / or parallel, metering devices, wherein at least one of the at least two metering devices is designed to meter material for the component, and at least one other of the at least two metering devices is formed, material for the component expedient at least temporarily variable to dose.

The device further comprises at least one output device to output the metered and / or variably metered material.

The component is advantageously produced such that it is provided with at least one continuous (in particular graded) or approximated continuous (in particular graded) property change in at least one spatial direction, preferably two or three spatial directions. The property change is expedient a functional property change.

For the sake of brevity, the "at least one continuous or approximated continuous property change" is usually referred to below as "continuous property change".

The continuous change in the properties advantageously makes it possible for the component to be adapted to a structural physical and / or structural structural requirement profile (which actually occurs). Thus, the component composition / structure preferably follows a building physics and / or structural requirement profile. As a result, it is possible, for example, to achieve an at least approximately homogeneous state of stress, an improvement in the thermal insulation properties and a multifunctionality (eg carrying, insulating, sealing) of the component. For example, by means of the continuous property change, an improvement in the component properties can be achieved by a local adaptation of the porosity and thus the strength and rigidity to actually occurring stress states in the component, eg by means of lightweight aggregates, pore formers, etc. Consequently, a mass and material savings and, for example, lower Component dimensions feasible, resulting in a more positive life cycle assessment leads compared to conventional components. In building construction, the mass and material savings also lead advantageously to a gain in usable space.

Furthermore, the continuous change in properties can ensure a permanent bond of component regions of different material, in particular concrete composition.

The continuous change in properties can be used in addition to the adaptation of the component to load-structural and structural-physical requirement profiles and the adaptation of the component to economic and environmental requirement profiles. Thus, for example, resource efficiency, CO ₂ -Fußabdruck reduction of embodied energy in the component, and / or improved recyclability, etc. can be achieved.

The continuous change in properties relates in particular to at least one of the following: thermal conductivity, strength, rigidity, bulk density, porosity, air-entraining, pigmentation, water content, fiber content, water vapor diffusion resistance, water penetration depth and content and type of aggregates, additives, additives and other possible component components, in particular concrete component components.

In particular, the invention makes it possible to produce varietally pure, e.g. purely mineral and yet multifunctional components. Thus, it is possible to dispense with a disadvantageous material mix that is not based on type of material (poor recyclability) and still advantageously achieve reduced component dimensions.

The component is particularly used in civil engineering and / or civil engineering and can be designed, for example, as part of the building shell, Exterior wall, cladding panel, as part of the structure, floor slab, beam, wall, beam, beam, column, column wall, foundation, noise barrier, exterior design, partition wall, tunnel wall, bridge construction, deck plate, tank, pipe, etc.

In one aspect of the invention, the continuous property change comprises, in particular, a flowing, graded, continuous and / or stepless change in property. In another aspect of the invention, the approximated continuous property change comprises in particular a stepwise or discontinuous property change, e.g. can be achieved by means of a multilayer structure or another suitable approximation structure. The approximated continuous property change, in particular the multi-layer structure, is preferably approximated to a continuous property change such that the deviation from the continuous property change is expediently negligible with regard to a structural-structural and / or structural-physical requirement profile to be achieved. For example, the approximated continuous property change may be approximated by a multilayer structure having at least 5, 10, 15, 20, 25, 50, 75 or 100 different layers to a continuous property change.

The property change can be formed in the component interior and / or on the surface of the component.

The at least one dispensing device is formed downstream of the at least two metering devices.

Preferably, the material supplied to a metering device is different from that of the other metering device supplied material, for example in nature, composition and / or Property. It is particularly preferred that the material fed to a metering device has reciprocal or opposite properties relative to the material supplied to the other metering device, for example one with high density, strength and thermal conductivity and the other with low density, strength and thermal conductivity.

The term "material" in the context of the invention includes in particular also materials and / or a material mixture, e.g. liquid material, granulated material, water, cement, aggregates, additives, additives, air pores, functional materials, gypsum, plaster, fibers, displacement bodies, foam plastic bodies, hollow bodies or other e.g. prefabricated functional bodies (of any size, geometry and / or density, for example with diameters of several centimeters, approximately greater than 5, 10, 15 or 20 cm, preferably of ultrahigh-strength fiber fine grain concrete), etc. and / or a mixture thereof. The material can be provided in quasi pure form and / or mixed form.

In the context of the invention, it is possible that the at least two metering devices are designed to dose material to form the component variable.

The device comprises a measure which ensures that a material which has been metered by one of the at least two metering devices and a material which has been variably metered by another of the at least two metering devices are mixed with one another. The at least one measure is formed downstream of the at least two metering devices. It is possible that the continuous property change is achieved by the variable metering and / or by varying the mixing ratio of the materials. The changeable Dosage and / or the variation is preferably carried out continuously (eg graded), in particular fluently.

For example, it is possible to mix from virtually pure starting materials or from premixed material mixtures, or a premixed material mixture or a quasi-pure starting material can be modified by admixing further materials / material mixtures.

It is possible that the device comprises at least one mixing device (eg a continuous mixer, a continuous mixer, a mixer mixing through the geometry of its mixing chamber, a static mixer, a dynamic mixer, a mixing device mixed by means of compressed air turbulence (eg with the aid of a Ring nozzle), etc.). Preferably, the mixing device is designed to mix a material which has been metered by one of the at least two metering devices and a material which has been variably metered by another of the at least two metering devices. For example, the mixing device can be arranged upstream of the at least one output device or within the at least one output device.

It is possible that the device has at least two, three or more than three preferably parallel arranged output devices to output material. The at least two dispensing devices are preferably arranged downstream of the at least two metering devices.

According to the invention, at least one first dispensing device is designed to dispense material that has been metered by one of the at least two dispensing devices by means of a spray jet, and a second dispensing device is configured, to output material which has been variably metered by another of the at least two metering devices by means of a spray jet. According to the invention, the at least one first and second output device are designed such that the material output from the first output device and the material output from the second output device mix by intersecting the spray jets. According to the invention, the mixing takes place in the spray mist and / or downstream outside the at least one first and second output devices or preferably generally outside the device. The sprays are preferably spray cones.

In one aspect of the invention, therefore, metered material can be mixed with variably metered material or variably metered material are mixed with variably metered material, in particular upstream, in and / or downstream of at least one output device. The intermixing is particularly continuous (e.g., graded, continuous).

According to the present invention, at least one of the at least two metering devices is formed (preferably the at least two metering devices) in order to continuously or variably meter material continuously variable. For example, the variable dosage may be varied over a period of at least 1, 5, 10, 15, 30, 60, 120, or 180 seconds. It is also possible for the at least two metering devices to dose conventionally, at least temporarily, appropriately.

Preferably, a continuously changed dosing in particular comprises a flowing, graded, continuous and / or continuous dosing. Especially In particular, an approximated, continuously varied metering comprises a stepwise or unsteady metering. The approximated continuously changed metering is in particular approximated by means of at least 5, 10, 15, 20, 25, 50, 75 or 100 approximation steps to a continuously changed metering, whereby the approximated continuous property change generated on the component compared to the continuous property change with respect to a achievable Tragstrukturelles and / or building physics requirement profile is expedient negligible. The at least one dispensing device is preferably a dispensing device for spraying off material, in particular in order to achieve a flat material application. Here, the spraying can be done for example by means of a wet or dry spray process. Preferably, the at least one output device comprises a compressed air connection in order to spray off material supported by compressed air.

It is also possible, but not part of the invention, for the at least one dispenser to be an infeed bar to remove material e.g. pour layer by layer, especially to achieve a linear material application. The insertion bar may e.g. Slit-shaped openings (for example, opposite and / or offset from each other), in particular for receiving material on one side and material output in a defined width on the other side. In this case, the output of the materials preferably takes place without compressed air.

It is also possible, but not part of the invention, for the at least one dispensing device to be a print head or a nozzle for dispensing material drop-shaped and / or continuously, in particular for point-wise, discrete and / or linear material application to achieve. Preferably, the output of the material takes place continuously and / or without compressed air.

The device comprises an automated movement device (guide device) for moving (guiding) the at least one output device. The moving means may comprise the at least one output means e.g. pivot, rotate, move horizontally, move vertically, move in an arc, etc .. The movement device is used in particular for exact positioning and / or aligning the at least one output device.

The movement device comprises a distributor mast or articulated arm (eg multi-joint distributor mast or multi-joint arm) or a gantry structure which is movable and / or movably arranged on the at least one dispensing device, preferably horizontally, axially and / or pivotably.

It is also possible for the movement device to comprise a robot, in particular a 5-axis or 6-axis robot.

It is possible for the movement device to comprise a preferably uniaxially and / or vertically movable holding structure which holds a multiplicity of, for example, grid-shaped output devices (eg at least three, four, eight or twelve). Advantageously, the output devices, for example, individually different (eg for multi-axis property change) or collectively the same (eg for uniaxial property change) can be controlled.

It is possible that the device has at least one detection device for detecting at least one component-specific, component-influencing and / or device-specific state parameter (for example state variable, state property, positioning, etc.). The detection may e.g. before, during and / or after the manufacture of the component.

The detection device is preferably movable together with the at least one output device and, e.g. attached to the at least one output device or to the movement device.

It is also possible for the detection device to be stationary, ie not moved with the output device or the movement device. The stationary detection device is e.g. positioned outside a formwork for the component or integrated in the formwork for the component.

It is possible for the device to have a detection device for detecting at least one material flow-specific state parameter, which is e.g. is present within the device (e.g., volume flow, state size, state property, etc.). The detection may e.g. before, during and / or after the manufacture of the component.

In the context of the invention, the component-specific state parameter comprises in particular at least one of the following: geometry, layer thickness, position, dimension, composition, texture and presence of the material application and thus of the component or at least a part thereof and any other properties characterizing the component or the material application. In the context of the invention, the component-influencing condition parameter comprises in particular at least one of the following: geometry, position, position, orientation and presence of a reinforcement for the component, an installation part for the component or in general other state parameters affecting the component and / or the production process that are present at the production location of the component, by means of at least one output device output material (eg spray jet (s), etc.), distance of the at least one output device for material application, formwork, installation part, etc. and also eg climatic state parameters such as air temperature, humidity, etc. The device-specific state parameter comprises within the scope of the invention in particular at least one of the following: position, position, orientation and speed of the at least one output device and / or the movement device and generally the device characterizing parameters (eg static and / or dynamic properties). Within the scope of the invention, the material flow-specific state parameter encompasses at least one of the following: one or more material volume flows, composition and consistency of the material volume flows, delivery pressure, etc. The above-mentioned state parameters may include, for example, changing, dynamic, static, immutable, etc. States, characteristics, properties, etc. act.

In the context of the invention, the detection comprises in particular measuring, measuring, detecting and / or monitoring. The at least one detection device can thus be a measuring device, measuring device, detection device and / or monitoring device (eg sensor, laser sensor, laser point sensor, 3D laser scanner, pressure sensor, etc.), whereby it can be determined, for example, whether the component is manufactured correctly.

Preferably, the device comprises a particular electronic control device (eg, a control and / or regulating device), which is preferably connected to at least one control section (eg, a controllable and / or controllable section) to at least one control section and / or dosing at least one of the at least two metering devices eg by means of at least one actuator, actuator, valve, or other suitable means of controlling (e.g., controlling and / or controlling), preferably in real time. In a particularly noteworthy embodiment of the invention, a control device is connected to one of the at least two metering devices in order to control the metering and / or connected to the other of the at least two metering devices in order to control the metering in such a way that it is variable; eg as mentioned above, as a function of at least one of the state parameters described above and / or a computer-generated model of the component to be produced described below.

The control device is preferably connected to at least one of the two detection devices and / or the at least one control section by means of a control circuit (control and / or regulating circuit).

The control device is preferably designed to control the at least one control section in dependence on the at least one state parameter detected by the first and / or second detection device, e.g. to control over the control circuit.

In addition, the control device is designed in particular in dependence on a computer-generated model (3D CAD design - CAD: Computer Aided Design) of the product to be produced Component, in particular this performing data / information to control the at least one control section. For this purpose, the control device may comprise, for example, a memory unit in which the computer-generated model, in particular this representative data / information can be stored, and / or an interface for transferring the computer-generated model, in particular this representative data / information, into the control device. The computer-generated model can include the component geometry to be achieved, the material structure to be achieved and / or the material composition of the component to be achieved (eg type, porosity, air pore content, pigmentation, distribution of the materials, composition of the materials, fiber and reinforcement content, mechanical properties, etc .).

In the context of the invention, an active control (control, regulation) or influencing of the at least one control section on the basis of a comparison of actual and desired state is possible, in particular by detecting at least one state parameter (actual size), comparing with target value. Size (eg from computer-generated model), appropriate control or influence of the control section, and if necessary, re-capture, compare, appropriate control, etc ..

It should be mentioned that the device has at least one, preferably two, conveying devices (eg pumps, screw pumps, etc.) for conveying the materials, which are preferably arranged upstream of the at least two metering devices. At least one of the at least two metering devices can be designed as a conveyor.

The at least one control section may e.g. one of the following: the one of the at least two metering devices to thereby advantageously control the metering, the other of the at least two metering devices to thereby advantageously control the variable metering, the at least one dispenser, a plurality of dispensers, e.g. individually different or collectively identically controllable, the at least one measure, the moving means and / or the at least two conveyors for conveying the materials and other suitable variable device parameters.

It should be noted that at least one of the at least two metering devices e.g. as a flow restrictor, valve, etc. may be formed.

It is possible that the device comprises at least three, four, eight or twelve dispensers, e.g. are arranged in a grid or in series adjacent to each other. As already mentioned above, it is possible that the output devices e.g. individually different (e.g., for multi-axis property change) or collectively the same (e.g., for uniaxial property change).

The at least two metering devices are arranged in particular in parallel and / or designed for independent metering. In addition, the at least two output devices are also arranged in particular in parallel, which also applies expediently to the at least two conveyors.

It should also be mentioned that the individual devices described above, such as the metering devices, the mixing device and / or the dispensing device, become devices can be summarized, which fulfill several of the functions mentioned at the same time.

Within the scope of the invention, it is possible for the metering to be carried out by means of the at least one metering device and the variable metering to be carried out by means of the at least one other metering device to be simultaneously, temporally overlapping and / or temporally spaced, e.g. is performed sequentially.

The invention also includes a method for producing at least one component, namely a concrete component. The method is preferably carried out with a device as described herein.

Preferably, in the method, material for forming the component is metered by means of at least one of at least two metering devices.

Furthermore, material for forming the component is variably metered by means of at least one other of the at least two metering devices. According to the invention, by means of at least one output device arranged downstream of the at least two metering devices, material is produced to produce the component and provided with at least one continuous or approximated continuous property change in at least one spatial direction, preferably two or three spatial directions.

Further method steps result from the above description concerning the device, which is referred to in order to avoid repetition.

• Es ist möglich, dass Material, das von der einen der zumindest zwei Dosiereinrichtungen dosiert wurde, und Material, das von der anderen der zumindest zwei Dosiereinrichtungen veränderlich dosiert wurde, miteinander vermischt werden, und vorzugsweise ein Mischungsverhältnis gebildet wird, wobei durch Variation des Mischungsverhältnisses die Eigenschaftsänderung erzielt wird.

The method of the invention may further comprise one or more of the following features:

• It is possible that material that has been metered by one of the at least two metering devices, and material that has been variably metered by the other of the at least two metering devices, are mixed together, and preferably a mixing ratio is formed, wherein by varying the mixing ratio Property change is achieved.

Further, material metered by one of the at least two metering devices and material variably metered by the other of the at least two metering devices may be mixed together by at least one mixing device upstream of the at least one dispenser or in the at least one dispenser is arranged.

At least one first dispenser dispenses material dispensed from one of the at least two dispensers by means of a spray jet, and a second dispenser dispenses material variably dispensed from the other of the at least two dispensers by means of a spray jet. The output from the first output device material and that of the second Issued output material material mix by overlapping the spray with each other.

According to the invention, at least one of the at least two metering devices meters material continuously or approximates continuously.

The at least one output device is moved by means of an automated movement device.

It is possible that at least one component-specific, component-influencing and / or device-specific state parameter is detected by means of at least one first detection device, wherein preferably the at least one detection device is moved together with the at least one output device or is stationary.

It is also possible for at least one material-flow-specific state parameter, which is present within the device for producing the component, to be detected by means of at least one second detection device.

A control device may expediently control at least one control section or the metering of at least one of the at least two metering devices, preferably in real time.

The control device may preferably control the at least one control section as a function of the at least one state parameter detected by the first and / or second detection device.

The control device may expediently control the at least one control section as a function of a computer-generated model of the component to be produced.

The at least one control section preferably comprises at least one of the following: one of the at least two metering devices, the other of the at least two metering devices, in particular to control the variable metering, the at least one dispensing device, a plurality of dispensing devices individually individually or collectively the same are controllable, the at least one mixing device, the movement device, and / or at least one of at least two conveyors for conveying the materials.

Figur 1:

zeigt schematisch eine Prinzipdarstellung einer Vorrichtung zum Herstellen eines Bauteils gemäß einer Ausführungsform der Erfindung,

Figur 2:

zeigt schematisch ein Mischprinzip gemäß einer Ausführungsform der Erfindung,

Figur 3:

zeigt schematisch ein Mischprinzip gemäß einer anderen Ausführungsform der Erfindung,

Figur 4:

zeigt schematisch ein Mischprinzip gemäß einer wiederum anderen Ausführungsformen der Erfindung,

Figur 5:

zeigt eine Ausführungsform gemäß der Erfindung, bei der ein Mischvorgang der Materialen zum Ausbilden des Bauteils stromaufwärts einer Ausgabeeinrichtung erfolgt,

Figur 6:

zeigt eine Ausführungsform gemäß der Erfindung, bei der ein Mischvorgang der Materialen zum Ausbilden des Bauteils innerhalb einer Ausgabeeinrichtung erfolgt,

Figur 7:

zeigt eine Ausführungsform gemäß der Erfindung, bei der ein Mischvorgang der Materialen zum Ausbilden des Bauteils stromabwärts außerhalb zweier Ausgabeeinrichtungen oder allgemein außerhalb der Vorrichtung zum Herstellen des Bauteils erfolgt,

Figur 8:

zeigt schematisch ein Materialauftragsprinzip gemäß einer Ausführungsform der Erfindung, bei dem die Materialien zum Ausbilden des Bauteils mittels eines Druckkopfes ausgegeben werden,

Figur 9:

zeigt schematisch ein Materialauftragsprinzip gemäß einer Ausführungsform der Erfindung, bei dem die Materialien zum Ausbilden des Bauteils mittels einer Einbringleiste ausgegeben werden,

Figur 10:

zeigt schematisch ein Materialauftragsprinzip gemäß einer Ausführungsform der Erfindung, bei dem die Materialien zum Ausbilden des Bauteils mittels einer Absprüheinrichtung abgesprüht werden,

Figur 11:

zeigt eine Bewegungseinrichtung in Form eines Verteilermastes oder Gelenkarms gemäß einer Ausführungsform der Erfindung,

Figur 12:

zeigt eine Bewegungseinrichtung in Form einer beweglichen Portalkonstruktion, an der eine Ausgabeeinrichtung beweglich montiert ist, gemäß einer Ausführungsform der Erfindung,

Figur 13:

zeigt eine Bewegungseinrichtung mit einer Vielzahl von in einem Raster angeordneten Ausgabeeinrichtungen gemäß einer Ausführungsform der Erfindung,

Figur 14:

zeigt eine schematische Darstellung von Zuständen, die vor und während der Herstellung des Bauteils vorzufinden sind, sowie mögliche Arten und Positionen von Erfassungseinrichtungen,

Figur 15:

zeigt eine schematische Prinzipdarstellung gemäß einer Ausführungsform der Erfindung, bei der die Materialien zum Ausbilden des Bauteils stromabwärts außerhalb zweier Ausgabeeinrichtungen im Sprühnebel miteinander vermischt werden,

Figur 16:

zeigt eine schematische Prinzipdarstellung gemäß einer anderen Ausführungsform der Erfindung, bei der die Materialien zum Ausbilden des Bauteils stromabwärts außerhalb dreier Ausgabeeinrichtungen im Sprühnebel miteinander vermischt werden,

Figur 17:

zeigt ein Bauteil mit eindimensional kontinuierlicher oder approximiert kontinuierlicher Eigenschaftsänderung gemäß einer Ausführungsform der Erfindung,

Figur 18:

zeigt ein Bauteil mit zweidimensional kontinuierlicher oder approximiert kontinuierlicher Eigenschaftsänderung gemäß einer Ausführungsform der Erfindung,

Figur 19:

zeigt ein Bauteil mit dreidimensional kontinuierlicher oder approximiert kontinuierlicher Eigenschaftsänderung gemäß einer Ausführungsform der Erfindung,

Figur 20:

zeigt eine schematische Prinzipdarstellung der Erzeugung und des resultierenden Gefüge-Aufbaus einer kontinuierlichen oder approximiert kontinuierlichen Eigenschaftsänderung gemäß einer Ausführungsform der Erfindung,

Figur 21:

zeigt ein Flussdiagram eines Verfahrens gemäß einer Ausführungsform der Erfindung, und

Figur 22:

zeigt ein Flussdiagram eines Verfahrens gemäß einer anderen Ausführungsform der Erfindung.

Other advantageous developments of the invention are disclosed in the dependent claims or will become apparent from the following description of the preferred embodiments of the invention in conjunction with the accompanying drawings.

FIG. 1:

shows schematically a schematic diagram of an apparatus for producing a component according to an embodiment of the invention,

FIG. 2:

shows schematically a mixing principle according to an embodiment of the invention,

FIG. 3:

shows schematically a mixing principle according to another embodiment of the invention,

FIG. 4:

shows schematically a mixing principle according to yet another embodiment of the invention,

FIG. 5:

shows an embodiment according to the invention, in which a mixing process of the materials for forming the component takes place upstream of an output device,

FIG. 6:

shows an embodiment according to the invention, in which a mixing process of the materials for forming the component takes place within an output device,

FIG. 7:

shows an embodiment according to the invention, in which a mixing operation of the materials for forming the component takes place downstream outside two dispensing devices or generally outside the device for producing the component,

FIG. 8:

12 schematically shows a material application principle according to an embodiment of the invention, in which the materials for forming the component are output by means of a print head,

FIG. 9:

12 schematically shows a material application principle according to an embodiment of the invention, in which the materials for forming the component are output by means of an insertion strip,

FIG. 10:

shows schematically a material application principle according to an embodiment of the invention, in which the materials for forming the component are sprayed by means of a spraying device,

FIG. 11:

shows a movement device in the form of a distribution boom or articulated arm according to an embodiment of the invention,

FIG. 12:

shows a moving device in the form of a movable portal construction, on which a Output device is movably mounted, according to an embodiment of the invention,

FIG. 13:

shows a moving device with a plurality of arranged in a grid output devices according to an embodiment of the invention,

FIG. 14:

shows a schematic representation of conditions that can be found before and during the manufacture of the component, as well as possible types and positions of detection devices,

FIG. 15:

shows a schematic diagram according to an embodiment of the invention, in which the materials for forming the component downstream of two dispensers are mixed together in the spray,

FIG. 16:

shows a schematic diagram of a principle according to another embodiment of the invention, in which the materials for forming the component downstream of three dispensers are mixed together in the spray,

FIG. 17:

shows a component with one-dimensional continuous or approximated continuous property change according to an embodiment of the invention,

FIG. 18:

shows a component with two-dimensional continuous or approximated continuous Property change according to an embodiment of the invention,

FIG. 19:

shows a component with three-dimensionally continuous or approximated continuous property change according to an embodiment of the invention,

FIG. 20:

2 shows a schematic basic representation of the generation and the resulting microstructure of a continuous or approximated continuous property change according to an embodiment of the invention,

FIG. 21:

shows a flowchart of a method according to an embodiment of the invention, and

FIG. 22:

shows a flowchart of a method according to another embodiment of the invention.

The embodiments shown in the figures are partially identical, with similar or identical parts being provided with the same reference numerals, and to the explanation of which reference is also made to the description of one or more other embodiments in order to avoid repetition.

FIG. 1 shows schematically an understanding of the invention facilitating schematic diagram of an apparatus 1 for manufacturing a component. The component to be manufactured is a concrete component. The device 1 has three separate, parallel-arranged metering devices 10, the can be supplied via three parallel feeds 20 with different materials for forming the component. The materials can be supplied to the three metering devices 10, for example in virtually pure form or as mixtures. The three metering devices 10 are designed to meter the material supplied to them continuously, in particular in a graded variable manner.

The device 1 comprises a measure 40.1, which ensures that the metered materials are mixed together. The measure 40.1 is formed by a mixing device which is arranged downstream of the three metering devices 10. The apparatus 1 also comprises three parallel conveyors 80 for conveying the materials. The apparatus 1 further comprises an output device 30 arranged downstream of the three metering devices and downstream of the measure 40.1 for dispensing the metered and mixed materials by means of a spray jet ST in order to produce a material application MA in a formwork 100 and to produce the component. The component is produced such that it is provided with at least one functional continuous property change in at least one spatial direction.

The device 1 also comprises a movement device 50 for moving the delivery device 30 during the manufacture of the component and a detection device 60, which is described with reference to FIGS FIGS. 11 to 14 be described in more detail.

Furthermore, the device 1 comprises a control section (in FIG. 1 schematically indicated by means of the arrow) and a control device (control / regulating device) 70 which is connected to the control section and the detection device 60 is. The control device 70 is designed to control the control section, for example by means of one or more actuators, depending on the state parameters detected by the detection device 60 and in dependence on a 3D CAD model (CAD: Computer Added Design) of the component to be produced. The control section comprises the movement device 50 and the three metering devices 10, which makes it possible in particular to control the continuous metering. It is also possible for the control section to comprise further devices of the device 1, for example the mixing device 40.1, the dispensing device 30 and the conveying devices 80. Likewise, the checking may alternatively or additionally be carried out as a function of detected material flow-specific state parameters which occur during the production process within the device 1 be present and detected by a further, not shown, connected to the control device 70 detection device.

FIG. 2 shows schematically a mixing principle. The mixing principle is based on two, for example, homogeneous starting mixtures A and B, which preferably have reciprocal properties (eg starting mixture A with high density, high strength and high thermal conductivity and starting mixture B with low density, low strength and low thermal conductivity). FIG. 3 shows schematically a mixing principle. The mixing principle is based on a starting mixture which is modified by mixing in other materials such as aggregates (eg gravel, sand, gravel or other common aggregates) and / or additives (eg color pigments, organic substances, fibers and other common concrete admixtures). FIG. 4 shows schematically a mixing principle.

The mixing principle is based on the fact that the materials for the formation of the component, such as water, cement, aggregates, additives, additives, are virtually mixed together in pure form. With reference to the FIGS. 2 to 4 For example, the continuous property change is achieved by varying the mixing ratio of the starting materials and, in particular, by suitably varying the dosage of the starting materials.

FIG. 5 shows a measure 40.1, which ensures that the different materials for the formation of the component are mixed together. The measure 40.1 comprises a mixing device, which is arranged upstream of the dispensing device 30. The mixing device may be, for example, a continuous mixer.

FIG. 6 shows a measure 40.2, which ensures that the different materials for forming the component are mixed together. The measure 40.2 comprises a mixing device which is accommodated in the output device 30. The mixing device may, for example, be a mixing device which generates a mixture by the geometry of its mixing chamber, or a mixing device which generates a mixture by compressed air turbulence (eg with the aid of an annular nozzle).

FIG. 7 shows a measure 40.3 according to an embodiment of the invention, which ensures that the different materials for forming the component are mixed together. The measure 40.3 comprises two output devices 30, which are designed such that the materials are emitted by means of spray jets and are mixed with one another by intersection of the spray jets, thus, downstream of the two dispensers 30. The mixing process can be carried out, for example, by means of a wet or dry spraying process, in which, preferably, for example, two homogeneous starting mixtures were preferably conveyed in parallel and metered separately.

FIG. 8 schematically shows a material order MA, which is not part of the invention. In the FIG. 8 shown dispenser 30 is designed as a printhead or nozzle to output the materials drop-shaped and / or continuously, whereby a pointwise or discrete material application is achieved. The material is applied without compressed air.

FIG. 9 schematically shows a material order MA, which is not part of the invention. The dispenser 30 is designed as an infeed rail to preferably pour the materials for forming the component in layers, thereby achieving a linear material coverage MA. The insertion strip comprises slot-shaped openings, which are arranged opposite to one another or offset from one another, for receiving material on one side and material delivery in a defined width on the other side. The width of the feed bar is less than or equal to the width of the formwork 100. The material is applied without compressed air.

FIG. 10 schematically shows a material application MA according to yet another embodiment of the invention. The dispensing device 30 is designed as a spraying device to spray off the materials for forming the component, whereby a flat material application is achieved. The spraying can take place by means of a wet or dry spraying process. The material is applied by means of compressed air.

FIG. 11 schematically shows a schematic diagram of an automated movement device 50 for moving the output device 30 according to an embodiment of the invention. The movement device 50 is a distributor boom or articulated arm with multiple degrees of freedom. The movement device 50 may be, for example, a 5-axis or 6-axis robot. The spray axis of the output device 30 can thus always be aligned orthogonal to the tangential plane at the job site. Suitable locations include: in situ, precast plant or field factory. This embodiment advantageously allows, for example, curved components. In the FIG. 11 shown arrows exemplify the movement possibilities of the movement device 50 by way of example.

FIG. 12 schematically shows a schematic diagram of an automated movement device 50 for moving the output device 30 according to an embodiment of the invention. The movement device 50 comprises a gantry structure on which an output device 30 is movably mounted, eg horizontally and vertically movable and pivotable as needed. The portal construction can be moved horizontally. In the FIG. 12 arrows shown symbolize the movement possibilities of the movement device 50 and the output device 30th

FIG. 13 shows an automated movement device 50 for moving a plurality of output devices 30 according to yet another embodiment of the invention. The moving device 50 includes a movable support structure that holds a plurality of raster output devices 30. The support structure and thus the grid of the plurality of output devices 30 are preferably uniaxial and in particular vertically movable. This can advantageously be an economical production level

Components are realized, e.g. in the precast plant. Advantageously stepless property transitions in Z-axis are also possible.

FIG. 14 12 shows a schematic representation of states which can be found before and during the production of the component at the production location of the component and a plurality of detection devices 60, 60 ', 60 "for detecting corresponding state parameters. The detection devices 60 and 60' are used for measuring and detecting component-specific ( eg composition, geometry, layer thickness, material density, component properties, etc.), component influencing (eg shuttering 100, reinforcement 101, built-in part 102, temperature, humidity, etc.) and device-specific (eg position, speed, orientation, etc. of the output device 30 or The detection device 60 'is stationary, independent of the output device 30 and embodied as a 3D laser scanner The detection device 60 "is in the formwork 100 integrated and can record eg the weight of the material order or the presence of material order. The detection device 60 "is designed as a pressure sensor.

The detection devices 60, 60 'and 60 "and their output data are integrated into the process chain for the production of the component and taken into account. In particular simultaneous detection of material flow-specific state parameters (eg one or more parallel material volume flows, consistency and / or composition of the material volume flows, delivery pressure, etc.) within the device 1 by means of a further detection device, not shown and feedback with a control circuit, the control of the control section (ie in particular the variable device parameters), which thus represents a control section, can take place in real time.

FIG. 15 schematically shows a schematic diagram according to an embodiment of the invention. The embodiment comprises two parallel arranged material containers X and Y, two parallel conveyors 80, two parallel metering devices 10 and two parallel dispensers 30. The two dispensers 30 each comprise a compressed air port 31 for compressed air assisted dispensing.

The material container X is provided for a starting mixture A. The starting mixture A is conveyed by the conveyor 80 to the metering device 10, metered by the metering device 10, and forwarded to the output device 30, which outputs the starting mixture A by means of a spray jet ST1. The material container Y is provided for a starting mixture B. The starting mixture B is conveyed by the other conveyor 80 to the other metering device 10, continuously metered by the other metering device 10 continuously variable, and forwarded to the other output device 30, which outputs the starting mixture B by means of a spray jet ST2. The dispensers 30 are formed so as to overlap the sprays ST1, ST2 to mix the raw materials A, B with each other.

FIG. 16 shows yet another embodiment of the invention, in which three output devices 30 are formed to output material by means of a respective spray jet ST1, ST2, ST3. One of the output devices 30 is fed supplements, another output device 30 is an output mixture is supplied and the remaining output device 30 are fed additives. The dispensers 30 are configured such that the supplement spray ST1, the source mixture spray ST3, and the auxiliary spray ST2 intersect to mix the aggregates, the starting mixture, and the additives.

FIG. 17 schematically shows a representation of a component BT with continuous (graded) or approximated continuous (graded) property change in a spatial direction. The varying circular diameters symbolize the property change of the material composition and thus of the component BT. Application examples are flat components, walls, cladding panels, etc.

FIG. 18 schematically shows a representation of a component BT with continuous (graded) or approximated continuous (graded) property change in two spatial directions. Again, the varying circle diameter symbolize the change in property of the material composition and thus of the component BT. Application examples are cylindrical components, columns, pipes, etc.

FIG. 19 schematically shows a representation of a component BT with continuous (graded) or approximated continuous (graded) property change in three spatial directions. Likewise, the varying circle diameters symbolize the change in the properties of the material composition and thus of the component BT. Application examples are floor slabs, beams, cantilevers, etc.

The FIG. 20 schematically shows the generation and the structure or the structure of the continuous (graded) or approximated continuous (graded) property changes by varying the material composition and in particular the mixing ratio of the metered by means of at least two metering devices 10 materials. Variable parameters include eg the content, the size, the packing density, the type, the orientation and the ratio of the different materials.

FIG. 21 FIG. 3 shows a flowchart of a method for manufacturing a component, which is carried out with the device 1, according to an embodiment of the invention.

In a step S1, a material A (virtually in pure form or as a mixture) is fed to a metering device 30. In a parallel step S1 ', a different kind of material B (virtually in pure form or as a mixture) is fed to another metering device 30.

In a step S2, the material A is e.g. controlled by a control device (e.g., controlled or regulated). In a parallel step S2 ', the material B is e.g. controlled by the control means (e.g., controlled or regulated) variably metered.

In a step S3, the material A is guided to an output device 30. In a parallel step S3 ', the material B is guided to another output device 30.

In a step S4, the material A is discharged from the one discharge device 30 by means of a spray jet, and the material B is discharged from the other discharge device 30 by means of a spray jet. The two sprays overlap to mix the materials A and B together. The mixing thus takes place downstream of the dispensers 30 in the spray. By means of suitable metering of the materials A and B, suitable variation of the mixing ratio of the materials A and B and suitable movement of the dispensers 30 by means of the movement means 50, a component with continuous or approximated continuous property change can be produced.

FIG. 22 shows a flow chart facilitating the understanding of the invention of a method for manufacturing a component, which is carried out with the device 1.

In a step S1, a material A (virtually in pure form or as a mixture) is fed to a metering device 30. In a parallel step S1 ', a material B (virtually in pure form or as a mixture) is conducted to another metering device 30.

In a step S2, the material A is e.g. controlled by a control device (e.g., controlled or regulated). In a parallel step S2 ', the material B is e.g. controlled by a control device (e.g., controlled or regulated) variably metered.

In a step S3, the material A is guided to an output device 30. In a parallel step S3 ', the material B is guided to the same output device 30.

In a step S4, the materials A and B are mixed within the dispenser 30 by means of a mixer. In an alternative embodiment, it is possible for the materials A and B to be mixed together upstream of the dispenser 30 by means of a mixer.

In a step S5, the intermixed materials A and B are discharged from the dispenser 30 to manufacture a component. The component is produced such that it is provided with a graded change in property in at least one spatial direction, preferably two or three spatial directions.

The in the Figures 21 and 22 parallel executed steps can also be performed, for example overlapping in time and / or in succession.

The invention is not limited to the preferred embodiments described above. Rather, a variety of variations and modifications are possible, which also make use of the inventive idea and therefore in the, as defined in the claims fall.

Claims (11)

1. Device for producing at least one concrete component, with

   - at least two metering devices (10), wherein at least one of the at least two metering devices (10) is configured to meter material for forming the component, and at least one other of the at least two metering devices (10) is configured to meter material in a changeable manner for forming the component,

   - at least one dispensing device (30) arranged downstream of the at least two metering devices (10), which is configured to dispense material in order to produce the component and provide it with at least one continuous or approximately continuous property change in at least one spatial direction, wherein the device comprises at least one first dispensing device (30) in order to dispense material, which has been metered by the one of the at least two metering devices (10), by means of a spray jet (ST1), and comprises a second dispensing device (30) in order to meter material, which has been metered by the other of the at least two metering devices (10) in a changeable manner, by means of a spray jet (ST2), and the at least one first and second dispensing devices (30) are configured such that the material dispensed from the first dispensing device (30) and the material dispensed from the second dispensing device (30) are mixed with one another by the intersecting of the spray jets (ST1, ST2), and

   - an automated movement device (50) for the movement of the at least one dispensing device (30), wherein the movement device (50) comprises a distributor mast or jointed arm or a portal structure, which is movable and/or at which the at least one dispensing device (30) is movably arranged.
2. Device according to claim 1, wherein the device comprises at least one means (40.1; 40.2; 40.3) which ensures that material which has been metered by the one of the at least two metering devices (10) and material which has been metered in a changeable manner by the other of the at least two metering devices (10) are mixed with one another and preferably form a mixing ratio wherein, by variation of the mixing ratio, the property change is achieved.
3. Device according to any one of the preceding claims, wherein at least one of the at least two metering devices (10) is configured to meter material continuously or approximately continuously in a changeable manner.
4. Device according to any one of the preceding claims, wherein:

   a) the at least one dispensing device (30) is a spray device, in order to spray material in particular in order to achieve a flat material application;
   and/or

   b) at least three dispensing devices (30) are arranged in a grid pattern.
5. Device according to any one of the preceding claims, wherein the movement device (50)

   - comprises a robot, in particular a 5-axis or 6-axis robot, and/or

   - comprises a holding structure which holds a plurality of dispensing devices (30) arranged in the form of a grid.
6. Device according to any one of the preceding claims, wherein the device comprises at least one first detection device (60) for the detection of at least one condition parameter, specific to the component, influencing the component, and/or specific to the device.
7. Device according to claim 6, wherein the first detection device (60)

   - is movable together with the at least one dispensing device (30), or

   - is stationary, in particular positioned outside a formwork (100) for the component or integrated in the formwork (100) for the component.
8. Device according to one of claims 6 or 7, wherein the device comprises a second detection device for the detection of at least one material flow-specific condition parameter, which is present inside the device.
9. Device according to claim 8, wherein the device comprises a control device (70), in order to control at least one control portion or the metering of at least one of the at least two metering devices (10), preferably in real time, wherein the control device (70) is configured to control the at least one control portion in dependence of the at least one condition parameter detected by the first and/or second detection device, and/or to control the at least one control portion in dependence of a computer-generated model of the component which is to be produced, or at least a part of the component which is to be produced.
10. Device according to claim 9, wherein the at least one control portion comprises at least one of the following:

    - the one of the at least two metering devices (10), in particular in order to control the metering,

    - the other of the at least two metering devices (10), in particular in order to control the changeable metering,

    - the at least one dispensing device (30),

    - a plurality of dispensing devices (30), which can be controlled individually differently or collectively in the same manner,

    - the movement device (50),

    - at least one of at least two conveying devices (80) to convey the materials.
11. Method for producing at least one concrete component, preferably performed by means of a device according to any one of the preceding claims, wherein

    - material for forming the component is metered by means of at least one of at least two metering devices (10),

    - material for forming the component is metered in a changeable manner by means of at least one other of the at least two metering devices (10),

    - material is dispensed by at least one dispensing device (30) arranged downstream of the at least two metering devices (10) in order to produce the component and provided it with at least one continuous or approximately continuous property change in at least one spatial direction, wherein at least one first dispensing device (30) dispenses material, which was metered by the one of the at least two metering devices (10), by means of a spray jet (ST1), and a second dispensing device (30) dispenses material, which was metered by the other of the at least two metering devices (10) in changeable manner, by means of a spray jet (ST2), and the material dispensed from the first dispensing device (30) and the material dispensed from the second dispensing device (30) are mixed with one another by the intersecting of the spray jets (ST1, ST2), and

    - the at least one dispensing device (30) is moved by means of an automated movement device (50), wherein the movement device (50) comprises a distribution mast or jointed arm or a portal structure, which is movable and/or at which the at least one dispensing device (30) is movably arranged.

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