Concrete Printer and Method for Erecting Structures Using a Concrete Printer

Abstract

The aim of the invention is to provide a concrete printer which allows complex concrete elements and structures to be erected within a short time with the inclusion of a reinforcement and surfacing process. The concrete printer according to the invention, in particular for producing concrete elements and structures, has a vertically (Z) movable jack lift (6) which can be moved on two perpendicular rails (3) by a first drive unit (5). The jack lift (6) is connected to a longitudinal crossbeam (7) oriented horizontally in the longitudinal direction (X), and the longitudinal crossbeam (7) is connected to two guide rails (8) oriented in the longitudinal direction (X). A transverse crossbeam (9) which is oriented perpendicularly to the longitudinal crossbeam (7) can be moved along the guide rails (8) by a second drive unit (10), and at least one working head (13) is provided which can be moved along the transverse crossbeam (9), comprises at least one concrete printing nozzle (11), and can be moved by a third drive unit (12). The actuation of all the drive units (4, 5, 10, 12) and the concrete printing nozzles (11, 11a, 11b) is carried out by a control unit (41). In the method according to the invention, supporting concrete (18) is first cast or dispensed from a supporting concrete nozzle (11a) for an outer contour (18) and/or an inner contour (18). Reinforcement rods (31) are then optionally inserted, and the intermediate spaces (47) between the supporting concrete portions (18) and optional reinforcement rods (31) are then cast with liquid concrete (19) from the liquid concrete nozzle (11b).

Claims

1. A concrete printer, in particular for the production of concrete elements and constructions, whereby a vertical (Z) moving lift truck (6) is arranged on two vertical tracks (3) with a first drive unit (5), whereby the lift truck (6) is connected with a longitudinal beam (7) in a longitudinal direction (X) horizontally and the longitudinal beam (7) is connected with two guide rails (8) in a longitudinal direction (X), whereby a a cross beam (9) oriented at a right angle to the longitudinal beam (7) can be moved along the guide rail (8) with a second drive unit (10) and at least one moving work head (13) is arranged on a concrete printer nozzle (111) that can move along the cross beam (9) and moved through a third drive unit (12), whereby the control of the drive units (5, 10, 12) and the concrete printer nozzles (11, 11a, 11b) is realised through a control unit (41).

2. The concrete printer according to claim 1, characterised in that the vertical tracks (3) are arranged on a carriage (2) whereby the carriage (2) preferably is arranged on a track (1) laid in a horizontal longitudinal direction (X) and can be moved through a fourth drive unit (4), whereby the control of the fourth drive unit (4) is realised through the control unit (41).

3. The concrete printer according to claim 1, characterised in that the longitudinal beam (7) and/or the cross beam (9) are designed as framework constructions, preferably as 3-belt or 4-belt framework constructions, whereby the framework constructions are preferably designed with dummy elements (15) made of fibre-reinforced plastics and with junctions (16) made of aluminium.

4. The concrete printer according to claim 1, characterised in that in particular the first, second and third drive units (5, 10, 12) are designed respectively as spindle drives (16) or toothed gear drives (17).

5. The concrete printer according to claim 1, characterised in that the work head (13) includes at least a supporting concrete nozzle (11a) to apply low-water supporting concrete (18) and at least a liquid concrete nozzle (11b) to apply water-saturated liquid concrete (19).

6. The concrete printer according to claim 1, characterised in that the concrete printing nozzles (11a, 11b) are equipped with one, two or multiple individual and/or grouped controllable nozzle connections (36) and therefore formed as mixed nozzles and/or switch nozzles.

7. The concrete printer according to claim 1 characterised in that the work head (!3) has at least a form printing nozzle (2), a smoothing unit (21), a bursting unit (22), an embossing roller (23), a milling unit (24), a grinding unit (25), a welding unit (26), a reinforcement gripper (27) and/or a suction unit (49).

8. The concrete printer according to claim 1, characterised in that the concrete printing nozzles (11a, 11b), the form printing nozzle (20), the smoothing unit (21), the bursting unit (22), the embossing roller (23), the milling unit (24), the grinding unit (25), the welding unit (26) and/or the reinforcement gripper (27) are arranged individually or combined with each other respectively on different work heads (13).

9. The concrete printer according to claim 1, characterised in that the concrete printer has a trimming unit (28), a bending unit (29) and/or a transport unit for reinforcer bars (31).

10. The concrete printer according to claim 1, characterised in that the concrete printer, preferably on the carriage (2), has at least a concrete pump (32) and/or at least a concrete mixing unit (33) and/or at least a storage container (34) for concrete and/or concrete additives.

11. The concrete printer according to claim 1, characterised in that the work head (13) in a work head intake (35) can be rotated at least by a vertical axis (43) through a rotating unit (45).

12. The concrete printer according to claim 1, characterised in that the work head (13) or aggregates from the work head (13) are designed as multiple axis robots (44).

13. The concrete printer according to claim 7, characterised in that the form nozzles (21) are at least arranged horizontally on the work head (13).

14. A method for creating concrete elements and constructions using a concrete printer according to claim 1, characterised in that initially supporting concrete (18) from a supporting concrete nozzle (11a) is initially cast or applied for an outer contour (18) and/or inner contour (18), then optionally reinforcing bars (31) are inserted and then the spaces (47) between the supporting concrete sections (18) and reinforcing bars (31) are cast with liquid concrete (19) from the liquid concrete nozzle (11b).

15. The method for creating constructions according to claim 14, characterised in that the concrete printer prints retaining elements (42) next to or with the outer contour (18) and/or inner contour (18) and/or that retaining elements (42) are installed through the gripper (27), then reinforcer bars (31) are placed in the retaining elements and the liquid concrete is printed from the concrete printing nozzles (11, 11a, 11b).

16. The method for creating constructions according to claim 14, characterised in that the sequence of the production of the outer contour (18) and/or inner contour (19), the production or placement of retaining elements (42), the arrangement of the reinforcer bars (31) and the application of liquid concrete (19) is repeated in layers.

17. The method for creating constructions using a concrete printer according to claim 1, characterised in that supporting concrete (18) will be applied around a basket with reinforced bars (31) through a supporting concrete nozzle (11a) and hereafter the spaces (47) between the supporting concrete sections (18) will be cast with liquid concrete (19) from the liquid concrete nozzle (11b).

18. The method for creating constructions according to claim 14, characterised in that the respective reinforcement reinforcing bar (31) are cut to the required length in the trimming unit (28), bent to the defined form in the bending unit (29), moved to the required position with the transport unit (30) and the reinforcement gripper (27) and/or the reinforcing bars (31) are welded together through the welding unit (26).

19. The method for creating constructions according to claim 14, characterised in that a form is created for the supporting concrete (18) and/or liquids (19) through the form nozzle (20).

20. The method for creating constructions according to claim 14, characterised in that a surface treatment of the external concrete layer occurs through a smoothing unit (21), bursting unit (22), embossing roller (23), milling unit (24) and/or grinding unit (25) parallel to the application of the concrete (18, 19) and/or directly following this.

21. The method for creating constructions using a concrete printer according to claim 1, characterised in that initially supporting concrete (18) from a supporting concrete nozzle (11a) is initially cast or applied for an outer contour (18) and/or inner contour (18), then optionally reinforcing bars (31) are inserted and then the spaces (47) between the supporting concrete sections (18) and reinforcing bars (31) are cast with liquid concrete (19) from the liquid concrete nozzle (11b).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Advantageous execution examples of the invention are explained in detail based on drawings.

[0050] The following is shown:

[0051] FIG. 1 a perspective view of a concrete printer,

[0052] FIG. 2 a perspective view of the lift truck,

[0053] FIG. 3 a perspective view of the crossbar and cross beam with work head,

[0054] FIG. 4 a perspective view of the work head with a concrete printer nozzle and reinforcement gripper

[0055] FIG. 5 structure of a concrete element with supporting concrete,

[0056] FIG. 6 layered structure of a concrete element,

[0057] FIG. 7 structure of a reinforcement basket with optional form print,

[0058] FIG. 8 a concrete printer nozzle with a nozzle connection,

[0059] FIG. 9 a concrete printer nozzle with two nozzle connections,

[0060] FIG. 10 a concrete printer nozzle with two external nozzle connections,

[0061] FIG. 11 a turret-shaped concrete printer nozzle arrangement,

[0062] FIG. 12 a printer head with three adjacent concrete printer nozzles,

[0063] FIG. 13 a printer head with three concrete printer nozzles arranged in a ring,

[0064] FIG. 14 a supporting concrete nozzle with a float,

[0065] FIG. 15 a supporting concrete nozzle with a rotating float,

[0066] FIG. 16 a supporting concrete nozzle with a bursting unit,

[0067] FIG. 17 a supporting concrete nozzle with embosser roller

[0068] FIG. 18 an arrangement of reinforced bars and

[0069] FIG. 19 an arrangement of reinforced bars with retaining elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0070] The FIGS. 1 to 3 show a concrete printer in a perspective view. FIG. 1 shows a perspective overall view of the concrete printer. In FIG. 2, the lift truck 6 is shown in more detail. FIG. 3 shows the cross bar 7 and cross beam 9 with a work head 13 in an enlarged illustration.

[0071] The illustrated concrete printer can be moved on a carriage 2 in the X-direction through a drive through a fourth drive unit 4 along a track 1. A lift truck 6 is arranged on the carriage 2 on the vertical rails 3 installed on the carriage 2.

[0072] The lift truck 6 can be changed in its height Z through a first drive unit 5 along the vertical track 3.

[0073] A cross beam 7 is arranged on the lift truck 6. The cross beam 7 is located parallel to the tracks 1 in the X-direction. Two guide rails 8one on the top and one on the bottomare mounted on the cross beam 7 in the X-direction. The cross bar 9 can be moved along these guide rails 8. A second drive unit 10, which works together with a toothed belt 17, is planned for this drive. Along the cross beam 9 oriented in the Y-direction, the work head 13 may be moved with a third drive unit 12 and a guide.

[0074] The drive units are electric motors that work together with a toothed belt 17 or a spindle drive 16. The spindle drive 16 may take on great strengths and is suitable for the lift ruck 6.

[0075] The toothed belt drive 17 allows for the execution of fast movements. Through the construction with lift truck 6, cross bar 7 and cross beam 9 as well as the drive units 4, 5, 10, 12, a free positioning of the work head 13 in the room is possible.

[0076] The movement of the concrete printer to the individual places of use is possible through the arrangement on a carriage 2 guided from a track 1 with the fourth drive unit 4. The tracks 1 may be laid in the shape of a ring as well. The concrete printer may also be designed as a track-independent vehicle that can move independently r be driven to the corresponding work sites in a hall or on a construction site, extends its supporting equipment and calibrates itself to realise the printing process. A trimming unit 28, a bending unit 29 and a transport unit 30 are arranged on the carriage 2. Reinforced bars 31 can be created correspondingly with this and moved into the work area of the reinforcement gripper 27 through the transport unit 30.

[0077] FIG. 4 shows a perspective view of the work head 13 with concrete printer nozzles 11a, 11b. The work head 13 is attached through a work head intake 35, which is found on the cross beam (not illustrated). The work head 13 consists of a printer head 46 with two side supporting concrete nozzles 11a, through which the supporting concrete (not illustrated) is transported and a liquid concrete nozzle 11b, through which the liquid concrete (not illustrated) is transported. A form printer nozzle 20 may also be arranged on the printer head 46, through which a form can be made of thermoplastic. The printer head 46 can be rotated 360 thanks to the motor-driven turning unit 45. The turning unit 45 allows for a rotation around a vertical axis 43 by, for example, 360 degrees. This makes it possible to have a very flexible positioning of the concrete printer nozzles 11a, 11b and the alignment to each other. Furthermore, a milling unit 24 is arranged on the printer head 46 here that allows for side surface processing.

[0078] The concrete printing nozzles 11a, 11b are equipped with nozzle connections 36 through which the concrete is fed through hoses (not illustrated). With multiple nozzle connections 36, if necessary, water and/or other additives may be added.

[0079] The form printing nozzle 20 is added thermally softening plastic. The form printing nozzle 20 is equipped with a cooling and/or heating unit for this purpose.

[0080] The work head 13 also includes a gripper 27, which is guided by a multiple axis robot 44. This makes it possible to executed diverse movements to pick up, align and position reinforced bars 31. With the gripper 27, form elements including affiliated supports as well as retaining elements that serve as a base for the reinforcer bars 31 can be positioned correspondingly.

[0081] Alternatively, the multiple axis robot 44 can be arranged with the gripper 27 on a separate work head 13. This makes the movements for printing and for placing the reinforcer bars 31 more independent of each other.

[0082] Just as with the gripper 27, a welding robot can be arranged on a work head 13 through the multiple axis robot 44.

[0083] In principle, it is intended for all aggregates to be able to be operated independent of each other. This makes it possible to activate individual aggregates, for example just the support concrete nozzle, as well as multiple aggregates, such as the gripper, welding robot and/or smoothing unit (all not illustrated), parallel to each other.

[0084] The FIG. 5 shows the structure of a concrete element with structures made of supporting concrete 18. The supporting concrete 18 is is applied in layers. Spaces 47 are filled by the supporting concrete 18. Through the reinforcement grippers 27, reinforcer bars 31 are placed in the spaces 47. In the following, the spaces 47 are filled with liquid concrete 19 from a liquid concrete nozzle (not illustrated).

[0085] FIG. 6 shows how a layered structure of a concrete element may be feasible using a concrete printer. Initially supporting concrete 18 is applied through the supporting concrete nozzle (not illustrated) to create an outer contour 18 and an inner contour 18. Retaining elements 42 made of supporting concrete 18 are also created in the same manner through the supporting concrete nozzles. The retaining elements 18 serve as a base for reinforcer bars 31. Through the corresponding arrangement of retaining elements 42, the reinforcer bars 31 may be installed in the concrete element corresponding to the reinforcement plan. Then they can be filled with liquid concrete (not illustrated). In the next step, the outer contours 18, the inner contour 18 and the retaining elements 42 are structured at a height so that the next layer of reinforcer bars 31 can be installed.

[0086] It is then followed again by a filling with liquid concrete. Concrete elements with reinforcement can be structured in this way. The filling with liquid concrete may optionally be executed at the end of the process. Vertical reinforcer bars (not illustrated) may be inserted in retaining elements 42 with vertical blind holes.

[0087] FIG. 7 shows the structure of a reinforcement basket with optional form printing. The structure of the reinforcement basket 31 made of reinforcer bars 31 is realised with a work head 13 mounted on a rotating unit 45. A reinforcement gripper 27, which is guided by a multiple axis robot 44 to place the reinforcer bars 31, is arranged on the work head 13. A welding unit 26 is arranged on another multiple axis robot 44. The welding unit 26 serves to weld the reinforcer bars 31 with each other.

[0088] Alternatively, a binding or clamping device may be arranged to connect the reinforcer bars 31 with each other. Through the multiple axis robot 44, the welding unit 26 and the reinforcement gripper 27 can be controlled independent of each other.

[0089] A form printing nozzle 20 is still arranged on the work head 13. The form printing nozzle 20 is designated for printing a form (not illustrated) that holds the concrete. The form may, for example, be structured as a wall made of thermoplastic. A net-shaped form may also be printed on the reinforcement basket 31.

[0090] Additionally, threads of plastic may be arranged correspondingly to connect the double-sided form walls through the form printer nozzle 20. Preferably thermoplastic is used as a form material. The form printing nozzle 20 is equipped with a cooling and/or heating unit for this purpose. Through the concrete printer nozzles 11a, 11b, the concrete is applied between the reinforcer bars 31 and, if necessary, the form net.

[0091] Instead of reinforcer bars 31 made of steel, reinforcer bars 31 made of other metals or plastics or similar materials such as carbon fibre may be used. It is also possible to make a construction as textile concrete. The reinforcement gripper 27 and other aggregates must then be designed so that they can position the threads or fabrics or knittings corresponding to the requirements. A reinforcement with plastic threads or carbon fibre threads may be executed by applying grains of sand on the liquid thermoplastic plastic. The same may be done correspondingly with the carbon fibre threads using bonding agents. This makes the surface of the respective threads rougher so that the fibres in or on the plastic and the grains of sand embedded in the concrete can better handle traction. The application of plastic threads or carbon fibre threads for reinforcement may occur correspondingly analogue to the form printer nozzle 20.

[0092] In FIG. 8, a concrete printer nozzle 11 with a side arranged nozzle connection 36 is illustrated. The nozzle connections are, for example, connected with hoses through fast couplings. The concrete is transported through the hoses using concrete pumps 32 from the concrete mixing unit 33 to the concrete printer nozzles 11.

[0093] FIG. 9 shows a concrete printer nozzle 11 with two nozzle connections 36. Through a switch found inside the nozzle, the concrete printer nozzle 11 can therefore act as a supporting concrete nozzle 11 a as well as a liquid concrete nozzle 11b. By mixing in the concrete printer nozzle 11, the concrete may be mixed with additives to harden faster or water to change the moisture of the concrete.

[0094] In FIG. 10, there is a concrete printer nozzle 11 with two external nozzle connections 36. In this way, a concrete printer nozzle 11 with a nozzle connection 36 can be equipped with two external nozzle connections 36 on a bivalent operation. In the nozzle connections 36, corresponding dosing units may exist for the controlled addition of concrete, water or additives. A corresponding mixing module to mix material may also be arranged in the concrete printer nozzle 11 or on the concrete printer nozzle 11.

[0095] FIG. 11 shows a turret-shaped printer head 46 with concrete printer nozzles 11a, 11b and corresponding nozzle connections 36 as well as a milling head 24. Through the rotation of the turret printer head 46, the liquid concrete nozzle 11b, the supporting concrete nozzle 11 a or the milling head 24 may be positioned as needed corresponding to the respective requirements.

[0096] FIG. 12 shows a printer head 46 with three concrete printer nozzles 11, 11a, 11b and corresponding nozzle connections 36 next to each other. The arrangement allows for the simultaneous operation of supporting concrete nozzles 11 a and liquid concrete nozzles 11b through a corresponding positioning. This makes the structure of concrete finished parts run faster in parallel operation of the concrete printer nozzles 11a, 11b. The arrangement of the concrete printer nozzles 11a, 11b can be designed parallel, crossways or diagonal to the alignment of the cross beam 9. Through a rotating unit 45 shown in FIG. 4, the alignment of the concrete printer nozzles 11a, 11b can be changed to each other corresponding to the requirements.

[0097] Finally, the concrete printer nozzles 11a, 11b can be arranged as desired in a ring-shape as shown in the example in FIG. 13.

[0098] FIG. 14 shows a support concrete nozzle 11a on which a smoothing unit 21 is mounted as a float 21 through a holder 48. The float 21 is there to apply the external concrete layer 18 from the applied concrete 18 and therefore to smooth the surface of the created supporting concrete 18 directly after applying concrete 18. The float 21 may also be designed as a rotating float 21 as shown in FIG. 15.

[0099] Instead of the float 21, a bursting unit 22 shown in FIG. 16 or an embossing roller 23 shown in FIG. 17 for surface treatment of the external concrete layer 18 of the created construction element may be aligned.

[0100] Thus, the surface treatment of the external concrete layer 18 may occur in a wet state directly after application of the supporting concrete 18.

[0101] FIG. 18 shows an example arrangement of reinforcer bars 31 in a view from above. The three crossing reinforcer bars 31 can therefore hold a reinforcer bar 31 arranged vertically in the middle (shown as a circle). The crossing reinforcer bars 31 are embedded at the ends, for example, in supporting concrete (not illustrated). Alternatively, the holding reinforcer bars 31 may also be bent or angled.

[0102] FIG. 19 shows an arrangement for holding a vertical reinforcer bar 31 through two retaining elements 42.

[0103] The retaining elements 42 are designed as discs here and are equipped with an opening in the middle through which the vertical reinforcer bar 31 is to be held. The discs from the retaining elements 42 are broken in the middle so that the liquid concrete (arrows) can flow through the retaining elements 42.

[0104] The wings of the retaining elements are embedded, for example, in supporting concrete (not illustrated).

[0105] For the holding of vertical reinforcer bars 31, perforated tape (not illustrated) may also be used, whereby the vertical reinforcer bars 31 may be placed through the openings of the perforated tape if necessary. The perforated tape in turn is embedded in the supporting concrete (not illustrated).

[0106] The placement of the retaining elements 42, the perforated tape and the reinforcer bars 31 is carried out preferably with the reinforcement gripper 27 from the concrete printer. The concrete 18, 19 that has not been completely attached through the smoothing unit 21, bursting unit 22, embosser roller 23, milling unit 24 and/or grinding unit 25 may be added to the concrete mixer unit 33 through a suction unit 49 and therefore used during the manufacturing process of the concrete 18, 19 in a type of recycling.

[0107] The suction unit 49 also serves to extract the grinding and milling dust as well as other particles that arise through the use of the milling unit 24 as well as the grinding unit 25.

LIST OF REFERENCE NUMERALS

[0108] 1Track

[0109] 2Carriage

[0110] 3Vertical track

[0111] 4fourth drive unit

[0112] 5first drive unit

[0113] 6lift truck

[0114] 7longitudinal bar

[0115] 8guide track

[0116] 9cross beam

[0117] 10second drive unit

[0118] 11concrete printer nozzle

[0119] 11 asupporting concrete nozzle

[0120] 11bliquid concrete nozzle

[0121] 12third drive unit

[0122] 13work head

[0123] 14dummy element

[0124] 15junction

[0125] 16spindle drive

[0126] 17toothed belt drive, toothed belt

[0127] 18supporting concrete, external concrete layer, outer contour, inner contour

[0128] 19liquid concrete

[0129] 20form printer nozzle

[0130] 21smoothing unit, float

[0131] 22bursting unit

[0132] 23embosser roller

[0133] 24milling unit, milling head

[0134] 25grinding unit

[0135] 26welding unit, welding robot

[0136] 27reinforcement gripper, gripper

[0137] 28trimming unit

[0138] 29bending unit

[0139] 30transport unit

[0140] 31reinforcer bar, reinforcer steel, reinforcement basket

[0141] 32concrete pump

[0142] 33concrete mixing unit

[0143] 34storage container

[0144] 35work head intake

[0145] 36nozzle connection

[0146] 41control unit

[0147] 42retaining elements

[0148] 43vertical axis

[0149] 44multiple axis robot

[0150] 45rotating unit

[0151] 46printer head, turret printer head

[0152] 47space

[0153] 48holder

[0154] Xlongitudinal direction, lengthwise

[0155] Ycross direction, cross

[0156] Zvertical direction, vertical, height change