NOZZLE DEVICE FOR PRODUCING A THREE-DIMENSIONAL COMPONENT, AND METHOD

Abstract

The invention relates to a nozzle device (100) for producing a three-dimensional component made of a material, in particular a shotcrete component made of concrete, a material application system (1), a manufacturing system (200) and a method for producing a three-dimensional component made of a material, in particular a shotcrete component made of concrete. In particular, the invention relates to a nozzle device (100) for producing a three-dimensional component made of a material, in particular a shotcrete component made of concrete, comprising a nozzle unit (101) with a material guide (102), which has a material inlet (104) for introducing a material, in particular a concrete, and a nozzle element (106) fluidically coupled to the material inlet (104) for applying the material, in particular the concrete, which is preferably arranged replaceably on the nozzle unit (101).

Claims

1. A nozzle device for producing a three-dimensional shotcrete component made of a concrete material, comprising a nozzle unit with a material guide, having a material inlet for introducing the concrete material, and a nozzle element fluidically coupled to the material inlet for applying the concrete material, which is replaceably arranged on the nozzle unit.

2. The nozzle device according to claim 1, comprising a nozzle element interface arranged and configured to form a connection of the nozzle unit to the nozzle element, and wherein the nozzle element interface comprises a material interface, a first compressed air interface, a second compressed air interface, and/or an accelerator interface.

3. The nozzle device according to claim 1, comprising a cleaning unit, which is configured to clean the nozzle unit and/or the nozzle element, with a pressurized fluid and/or a cleaning element.

4. The nozzle device according to claim 1, comprising a blow-out unit for cleaning the nozzle device, and wherein the blow-out unit and the nozzle unit are configured such that material components not usable by the nozzle unit are disposed of by the blow-out unit.

5. The nozzle device according to claim 1, comprising a material flow control unit acting within the material guide for controlling a concrete material flow, which is configured as a pinch valve, and/or a concrete material pressure sensor within the material guide.

6. The nozzle device according to claim 1, comprising: a sensor unit for geometry correction, wherein the sensor unit comprises at least one radar module or is formed as a radar module, and the radar module is configured to detect a spacing between the nozzle device and a concrete material layer applied with the nozzle device, and/or wherein the sensor unit comprises at least one profile sensor module for detecting dimensions of a concrete material layer applied with the nozzle device or is configured as a profile sensor module for detecting dimensions of the concrete material layer applied with the nozzle device.

7. The nozzle device according claim 1, comprising a vibration unit for introducing vibrations, which is configured to introduce the vibrations into the nozzle unit and/or nozzle device.

8. The nozzle device according to claim 1, comprising a control device arranged and configured to receive a distance signal characterizing a distance between the nozzle element and a generated concrete material layer from the sensor unit, and/or receive a size signal characterizing a dimension of the generated concrete material layer, and generate a control signal for controlling a handling unit guiding the nozzle unit based on the distance signal and/or the size signal, and/or receive a consistency signal characterizing a material consistency of the concrete material and generate and transmit a consistency correction signal, and/or receive a clogging signal characterizing a clogging or detect a clogging and cause a cleaning with a cleaning signal, by a cleaning unit, and/or generate a replacement signal causing a handling unit to replace the nozzle element, and/or initiate and/or terminate a concrete material application by controlling a material flow control unit.

9. The nozzle device according to claim 1, comprising a first concrete atomization unit arranged and configured to mix and/or atomize the concrete material with air, and/or a second concrete atomization unit arranged and configured to mix and/or atomize the concrete material with air and an accelerator, wherein the nozzle element comprises the first concrete atomization unit and/or the second concrete atomization unit.

10. The nozzle device according to claim 9, comprising a first compressed air input coupled to a first pressure sensor, and/or a second compressed air input coupled to a second pressure sensor, wherein the first pressure sensor is coupled to the first concrete atomization unit and/or the second pressure sensor is coupled to the second concrete atomization unit.

11. The nozzle device according to claim 9, comprising a two-substance nozzle for atomizing the accelerator with compressed air, and a broaching unit, comprising a needle valve, arranged and configured to clean the two-substance nozzle by broaching material, wherein the broaching unit comprises a broach for movement into the two-substance nozzle, wherein the two-substance nozzle is arranged upstream of the first concrete atomization unit and/or upstream of the second concrete atomization unit in a concrete material flow direction.

12. The nozzle device according to claim 1, comprising a temperature sensor for determining the temperature of the concrete material, the temperature sensor being arranged within the material guide, and/or a temperature control unit for tempering the concrete material, by heating and/or cooling a compressed air to be supplied to the concrete material.

13. A material application system for producing a three-dimensional shotcrete component made of a concrete material, comprising a nozzle device, comprising a nozzle unit with a material guide, having a material inlet for introducing the concrete material, and a nozzle element fluidically coupled to the material inlet for applying the concrete material, which is replaceably arranged on the nozzle unit, wherein the nozzle device is coupled to a concrete material supply unit configured to provide the concrete material to the nozzle unit.

14. The material application system according to claim 13, comprising a cleaning device configured to clean the nozzle element, wherein the cleaning device comprises or is configured as a fluid-carrying cleaning lance.

15. The material application system according to claim 13, comprising a first fluid supply unit which is coupled to the nozzle device and configured to supply a first fluid to the nozzle device.

16. The material application system according to claim 15, wherein the first fluid supply unit is coupled to the concrete material supply unit via a material supply line between the concrete material supply unit and the nozzle device, and a compressed air valve is arranged between the first fluid supply unit and the material supply line to control flow of the first fluid flow to the material supply unit.

17. The material application system according claim 13, comprising an admixture supply unit which is coupled to the nozzle device such that an admixture is suppliable to the concrete material within the nozzle device.

18. The material application system according to claim 17, comprising a second fluid supply unit which is coupled to the nozzle unit, the nozzle device, the material supply unit, the first fluid supply unit and/or the admixture supply unit to supply a second fluid thereto.

19. A manufacturing system, comprising the material application system according to claim 13, and a first handling unit for moving the nozzle device to apply the concrete material, and/or a second handling unit for handling and replacing the nozzle element.

20. A method of manufacturing a three-dimensional shotcrete component made of a concrete material, comprising the steps of: providing a nozzle device comprising a nozzle unit with a material guide, having a material inlet for introducing the concrete material, and a nozzle element fluidically coupled to the material inlet for applying the concrete material, wherein the nozzle element is replaceably arranged on the nozzle unit, and spraying the concrete material with a first nozzle element arranged on the nozzle unit.

21. The method according to of the preceding claim 20, wherein the first nozzle element is replaceably disposed on the nozzle unit, the method comprising the steps of: removing the first nozzle element and arranging a second nozzle element on the nozzle unit, and spraying the concrete material with the second nozzle element replaceably arranged on the nozzle unit.

22. The method according to claim 21, comprising the step of: cleaning the first nozzle element and/or the second nozzle element while it is or they are arranged on the nozzle unit and/or while it is or they are stored in a nozzle element rest, wherein the cleaning is performed with a fluid, with a cleaning element and/or with a cleaning device, and/or wherein the cleaning is performed in predefined cleaning cycles and/or when a blockage is detected.

23. The method according to claim 20, comprising the step of: detecting a spacing between the nozzle device and a concrete material layer applied with the nozzle device, and/or detection of dimensions of the concrete material layer applied by the nozzle device.

Description

[0075] Preferred embodiments are explained by way of example with reference to the accompanying figures. They show:

[0076] FIG. 1: a schematic, two-dimensional view of an exemplary embodiment of a material application system;

[0077] FIG. 2: a schematic, two-dimensional detailed view of an exemplary embodiment of a nozzle device;

[0078] FIG. 3: a further schematic, two-dimensional detailed view of an exemplary embodiment of a nozzle device;

[0079] FIG. 4: a schematic, two-dimensional view of an exemplary embodiment of a manufacturing system; and

[0080] FIG. 5: a schematic procedure.

[0081] In the figures, identical or essentially functionally identical or similar elements are designated with the same reference signs.

[0082] FIG. 1 shows a material application system 1. The material application system 1 comprises a nozzle device 100, a concrete supply unit 2, a first fluid supply unit, which is designed as a compressed air supply unit 14, an accelerator supply unit 28 and a second fluid supply unit, which is designed as a water supply unit 34. The concrete supply unit 2, the compressed air supply unit 14 and the accelerator supply unit 28 are connected to the nozzle device 100 by means of lines, in particular fluidically coupled.

[0083] The concrete supply unit 2 is fluidically coupled to the material line 10 with the nozzle device 100. A first concrete pressure sensor 6 and a concrete volume flow sensor 8 act within the material line 10. Furthermore, the concrete supply unit 2 is coupled to a waste water unit 4, wherein the waste water unit 4 comprises a pinch valve.

[0084] The compressed air supply unit 14 is coupled to the nozzle device 100 by means of compressed air lines, two compressed air lines leading from the compressed air supply unit 14 to the nozzle device 100. A first compressed air line comprises a first temperature control unit 16 and a first mass flow controller 18. By means of the first temperature control unit 16, the temperature of the compressed air provided can be controlled or set. By means of the first mass flow controller 18, a mass flow of the compressed air provided can be adjusted.

[0085] Analogous to the first compressed air line, a second compressed air line comprises a second temperature control unit 20 and a second mass flow controller 22. Furthermore, a pressure regulator 24 is provided between the second mass flow controller 22 and the nozzle device 100 for withdrawing a pressure-controlled compressed air, the outgoing line likewise leading into the nozzle device 100 and, in particular, being fluidically coupled to the two-substance nozzle 149 for atomizing the accelerator. In addition, a fluidic connection between the compressed air supply unit 14 and the material line 10 can be established by means of a compressed air valve 12 and between the compressed air supply unit 14 and the accelerator supply unit 28 can be established by means of a compressed air valve 26, wherein the compressed air can be used to clean the lines with compressed air.

[0086] The accelerator supply unit 28 is also coupled to the nozzle device 100 via a line. An accelerator pressure sensor 30 and an accelerator volume flow sensor 32 are provided within this line.

[0087] The water supply unit 34 is fluidically coupled to the concrete supply unit 2 and the accelerator supply unit 28 to enable cleaning of the lines with water. Water valves 36-40 are provided for this purpose. The material application system 1 further comprises a cleaning device 46 with a cleaning lance 110. The cleaning lance 110 is insertable into the nozzle element with a cleaning section. Furthermore, a high pressure line 42 extends from the water supply unit 34, by means of which a nozzle element 106 can be cleaned in combination with the cleaning lance 110 and a high pressure pump 44. For example, the water supply unit 34 may provide a fluid that exits from a cleaning opening of the cleaning lance 110.

[0088] Furthermore, the nozzle device 100 comprises a cleaning unit 160, which is arranged to clean the nozzle unit 101 and/or the nozzle element 106, in particular with a pressurized fluid, preferably water, and/or a cleaning element, in particular a cleaning pig.

[0089] FIGS. 2 and 3 show a detailed view of the nozzle device 100. Concrete reaches the material inlet 104 via the material line 10. The material inlet 104 is coupled to a material guide 102, which in particular extends from the material inlet 104 towards the nozzle element 106. Downstream of the material inlet 104, a viscosity sensor 158 is arranged to measure the consistency, in particular the viscosity, of the material, in this case concrete.

[0090] Furthermore, the nozzle device 100 comprises a first compressed air inlet 136 with a first pressure sensor 138 and a second compressed air inlet 140 with a second pressure sensor 142. Furthermore, the nozzle device 100 comprises a third compressed air inlet 144 for the compressed air tapped at the pressure regulator 24, which is fluidically coupled to the two-substance nozzle 149. Further, the nozzle device 100 includes an accelerator inlet 146 having an accelerator pressure sensor 148 fluidly coupled to the two-substance nozzle 149. In the two-substance nozzle 149, the accelerator is atomized with the supplied compressed air.

[0091] The material guide 102 is arranged such that the material, in particular concrete, can be moved from the material inlet 104 to the nozzle element 106. A second concrete pressure sensor 152 is further provided within the material guide 102, as well as a material flow control unit 154 that can act as a concrete valve. A concrete flow can be started or stopped by actuating the material flow control unit 154.

[0092] Downstream of the material flow control unit 154, a temperature sensor 134 is provided. The temperature sensor 134 preferably sends a temperature signal to a control device 156, which in turn controls the first temperature control unit 16 and/or the second temperature control unit 20 to control a temperature of the concrete. Further downstream, the concrete enters the nozzle element 106, which includes a first concrete atomization unit 114 and a second concrete atomization unit 118. In the first concrete atomization unit 114, the concrete is mixed with a compressed air. The compressed air is provided to the first concrete atomization unit 114 by means of a compressed air supply line 116 coupled to one of the compressed air inlets 136, 140. In the second concrete atomization unit 118, the concrete is further mixed with additional compressed air and an atomized accelerator. The compressed air and atomized accelerator are provided to the second concrete atomization unit 118 by means of the compressed air and accelerator supply line 120. The compressed air for the second concrete atomization unit is preferably provided at the compressed air inlet 136, 140 that is not fluidly coupled to the first concrete atomization unit 114. Compressed air and accelerator supply line 120 is further fluidly coupled to two-substance nozzle 149.

[0093] For cleaning the nozzle device 100, it is provided with a blow-out unit 130 having a blow-out 132, for example a blow-out opening.

[0094] The nozzle device 100 further comprises a sensor unit 122. The sensor unit 122 comprises a radar module 124 and a profile sensor module 126. The radar module 124 is preferably arranged to detect a distance between the nozzle device 100 and a material layer applied with the nozzle device 100. The profile sensor module 126 is particularly configured to detect dimensions of a layer of material applied with the nozzle device 100.

[0095] The nozzle device 100 further includes a nozzle element interface 128 arranged and configured to form a connection of the nozzle unit 101 to the nozzle element 106.

[0096] The nozzle element 106 preferably extends from the distal spray end 112 to a proximal material inlet end. A cavity preferably extends from the material inlet end to the spray end 112. Within the cavity, concrete may pass from the material inlet end toward the spray end 112. The material inlet end faces the nozzle unit 101 in intended operation. The spray end 112 faces away from the nozzle unit 101 in intended operation. The cross-section of the nozzle element adjacent to the spray end 112 may, for example, have a dimension of 3 mm to 48 mm.

[0097] The nozzle element 106 is replaceably arranged on the nozzle unit 101. The nozzle element interface 120 is set up in such a way that the nozzle element 106 can be automatically removed from the nozzle unit 101 and arranged again on the nozzle unit 101.

[0098] The nozzle device 100 further comprises an ultrasonic unit 150. The ultrasonic unit 150 is arranged to introduce vibrations into the nozzle unit 101 and/or nozzle device 100 and/or into the nozzle element 106. The ultrasonic vibrations improve the spray quality.

[0099] FIG. 4 shows a manufacturing system 200 with a first handling unit 202 and a second handling unit 204. A material application system 1 is arranged on the first handling unit 202. In particular, it is preferred that only the nozzle device 100 is moved by the first handling unit and the other components of the material application system 1 are arranged statically and coupled to the nozzle device 100, for example, by means of elastic lines. In particular, the second handling unit 204 of the manufacturing system 200 is arranged and configured to remove the nozzle element 106 from the nozzle unit 101 and to arrange a second nozzle element 108 on the nozzle unit 101.

[0100] With the material application system 1 and/or with the manufacturing system 200 and/or with the nozzle device 100, a process for producing a three-dimensional component made of a material, in particular a shotcrete component made of concrete, can be realized in an advantageous manner. In particular, these components enable a fully automated process with independent error handling, which reduces the manual effort and can thus be operated by only one person. Furthermore, the manufacturing system 200, the material application system 1 and/or the nozzle device 100 reduces scrap and rework due to a higher process quality.

[0101] Furthermore, a higher accuracy between CAD planning and production process is enabled, which reduces the development efforts for new components. Furthermore, the manufacturing system 200, the material application system 1 and/or the nozzle device 100 can be used flexibly, since the system can be used in cold and also in hot regions due to the temperature compensation. Furthermore, the manufacturing system 200, the material application system 1 and the nozzle device 100 enable new use cases for the production of three-dimensional concrete components, namely by adjusting the application geometry during the ongoing process.

[0102] FIG. 5 shows a method for producing a three-dimensional component made of a material, in particular a shotcrete component made of concrete. In step 300, a material is applied, in particular sprayed, which may be concrete, for example. The application is performed with a first nozzle element 106 replaceably arranged on a nozzle unit 101. In step 302, the first nozzle element 106 is removed and a second nozzle element 108 is arranged. In step 304, a material is applied, in particular sprayed, with the second nozzle element 108 replaceably arranged on the nozzle unit 101. In step 306, the first nozzle element 106 and/or the second nozzle element 108 is/are cleaned while arranged on the nozzle unit 106. In addition, cleaning may also be performed while they are stored in a nozzle element rest.

[0103] In step 308, a detection of a spacing between the nozzle unit 101 and a material layer applied with the nozzle unit 101 is performed. In step 310, the dimensions of the material layer applied with the nozzle unit 101 are detected.

REFERENCE SIGNS

[0104] 1 Material application system

[0105] 2 Concrete supply unit

[0106] 4 Wastewater unit with pinch valve

[0107] 6 first concrete pressure sensor

[0108] 8 Concrete volume flow sensor

[0109] 10 Material line

[0110] 12 Compressed air valve

[0111] 14 Compressed air supply unit

[0112] 16 First temperature control unit

[0113] 18 First mass flow controller

[0114] 20 Second temperature control unit

[0115] 22 Second mass flow controller

[0116] 24 Pressure regulator

[0117] 26 Air valve

[0118] 28 Accelerator supply unit

[0119] 30 Accelerator pressure sensor

[0120] 32 Accelerator volume flow sensor

[0121] 34 Water supply unit

[0122] 36 First water valve

[0123] 38 Second water valve

[0124] 40 Third water valve

[0125] 42 High pressure line

[0126] 44 High pressure pump

[0127] 46 Cleaning device

[0128] 100 Nozzle device

[0129] 101 Nozzle unit

[0130] 102 Material guide

[0131] 104 Material inlet

[0132] 106 Nozzle element

[0133] 108 Second nozzle element

[0134] 110 Cleaning lance

[0135] 112 Spray end

[0136] 114 Concrete atomization unit

[0137] 116 Compressed air supply line

[0138] 118 Second concrete atomization unit

[0139] 120 Compressed air and accelerator supply line

[0140] 122 Sensor unit

[0141] 126 Profile sensor module

[0142] 128 Nozzle element interface

[0143] 130 Blow-out unit

[0144] 132 Blow-out

[0145] 134 Temperature sensor

[0146] 136 First compressed air inlet

[0147] 138 First pressure sensor

[0148] 140 Second compressed air inlet

[0149] 142 Second pressure sensor

[0150] 144 Third compressed air inlet

[0151] 146 Accelerator inlet

[0152] 148 Accelerator pressure sensor

[0153] 149 Two-substance nozzle

[0154] 150 Ultrasonic unit

[0155] 152 Second concrete pressure sensor

[0156] 154 Material flow control unit

[0157] 156 Control device

[0158] 158 Viscosity sensor

[0159] 160 Cleaning unit

[0160] 200 Manufacturing system

[0161] 202 First handling unit

[0162] 204 Second handling unit