MANUFACTURING SYSTEM FOR ADDITIVE PRODUCTION OF COMPONENTS, AND METHOD

Abstract

The invention relates to a manufacturing system (1) for additively producing concrete components, in particular for carrying out a spraying process for additively producing concrete components, a method for additively producing a concrete component, in particular using a shotcrete process, and a method for setting up a manufacturing system (1). In particular, the invention relates to a manufacturing system (1) for the additive production of structural components, preferably concrete structural components, in particular for carrying out a spraying process, preferably a shotcrete process, for the additive production of structural components, preferably concrete structural components, comprising a first manufacturing module (100) having a mixing unit (106) for producing a composite material, preferably a concrete, in particular by mixing a first material component, preferably a first concrete component, and a second material component, preferably a second concrete component, and a second manufacturing module (200) with a first handling unit (212) for additive production of a component with the composite material, in particular for production of a sprayed component, preferably a shotcrete component, wherein the first manufacturing module (100) and the second manufacturing module (200) are coupled by means of a conveyor unit (112).

Claims

1. A manufacturing system for the additive production of concrete components, comprising a first manufacturing module with a mixing unit configured to produce a composite concrete material by mixing a first concrete component and a second concrete component, and a second manufacturing module comprising a first handling unit for additive production of a component with the composite concrete material, wherein the first manufacturing module and the second manufacturing module are coupled by a conveyor unit.

2. The manufacturing system according to claim 1, wherein: the first manufacturing module and the second manufacturing module are formed separately from one another, and the first manufacturing module and the second manufacturing module being transportable and/or installable separately from one another.

3. The manufacturing system according to claim 1, wherein the first manufacturing module comprises a supply unit for providing the first concrete component and/or the second concrete component, wherein the supply unit comprises a first supply module for providing the first concrete component and a second supply module for providing the second concrete component.

4. The manufacturing system according to claim 1, wherein the first manufacturing module comprises: a pump unit, wherein a vibration unit is arranged between the mixing unit and the pump unit, and/or the pump unit comprises the vibration unit, and/or a cleaning system for automated cleaning of the mixing unit, of the pump unit, of an application unit and/or of auxiliary units, wherein the cleaning system comprises a fluid pump for discharging a cleaning fluid and the cleaning system is fed with treated water and/or to treat water.

5. The manufacturing system according to claim 1, wherein: the first manufacturing module has a first metering unit and/or weighing unit, which is/are set up to set a component-specific mixing ratio between the first concrete component and the second concrete component.

6. The manufacturing system according to claim 1, wherein: the second manufacturing module comprises a second handling unit for performing support processes, for finishing the composite concrete material, for inserting reinforcing elements, for inserting component parts and/or for integrating components for securing the transport of the component parts.

7. The manufacturing system according to claim 1, wherein the second manufacturing module comprises: a rotary table for rotating the component, and/or a first tool exchange system for exchanging tools used by the first handling unit and/or a second handling unit of the second manufacturing module.

8. The manufacturing system according to claim 1, wherein the first handling unit and/or a second handling unit of the second manufacturing module is/are arranged in a location-flexible manner, wherein the first handling unit and/or the second handling unit is/are arranged on a linear axis.

9. The manufacturing system according to claim 1, wherein the second manufacturing module comprises at least two separate submodules, wherein: a first submodule comprises the first handling unit and/or a second submodule comprises a second handling unit of the second manufacturing module and/or a third submodule comprises the turntable, wherein at least two of the submodules are designed to be transportable separately from each other.

10. The manufacturing system according to claim 1, comprising a third manufacturing module with a feeding unit for providing material components comprising additives, the additives comprising one or more of powdery, fibrous and/or liquid additives, and/or admixtures and/or binders, wherein the feeding unit comprises a feeding device and a conveying unit and/or a metering unit.

11. The manufacturing system according to claim 10, wherein the third manufacturing module comprises: a second weighing unit arranged to weigh and/or meter binders, and/or comprises a further weighing unit arranged to weigh and/or meter additives and/or admixtures, and/or further metering units, which are set up to meter admixtures and/or additives, and/or a coolant unit comprising a flake ice unit for producing and/or providing ice for cooling the composite concrete material.

12. The manufacturing system according to claim 1 comprising a third manufacturing module, wherein the first manufacturing module, the second manufacturing module, the third manufacturing module and/or one, more or all of a plurality of submodules have a housing and/or are configured as a transport unit, side walls of the housing being at least partially openable, an upper housing part being extendable and/or liftable, and/or have side walls, floors and/or ceilings which have heat-insulating and/or sound-insulating material.

13. The manufacturing system according to claim 1 comprising a third manufacturing module, wherein: the first manufacturing module, the second manufacturing module, the third manufacturing module and/or one, more or all of a plurality of sub-modules comprises a first floor and a second floor spaced in vertical direction for forming an intermediate space between the first floor and the second floor, a drain channel for disposal of cleaning fluid being arranged in the intermediate space.

14. A method for the additive production of a concrete component comprising the steps of: providing a a first concrete component and a second concrete component at a supply unit of a manufacturing system, generating a composite concrete material by mixing the first concrete component and the second concrete component in a mixing unit of the manufacturing system, and additively producing the concrete component with the composite concrete material using a spraying process with a first handling unit.

15. The method according to the preceding claim 14, comprising the step or steps of: metering the first concrete component and the second concrete component in a component-specific mixing ratio, and/or vibrating and/or pumping the composite concrete material from the mixing unit to the first handling unit, and/or finishing of the concrete component, including insertion of a reinforcement element and/or insertion of component parts and/or integration of components for component transport.

16. A method for setting up a manufacturing system for the additive production of concrete components, comprising the steps: providing a first manufacturing module with a mixing unit for generating a composite concrete material by mixing a first concrete component and a second concrete component, providing a second manufacturing module with a first handling unit for additively manufacturing a concrete component with the concrete, and coupling the first manufacturing module and the second manufacturing module in such a way that the composite concrete material generated in the mixing unit can be brought to the first handling unit.

17. The manufacturing system according to claim 1, wherein the manufacturing system is configured to carry out a shotcrete process for the additive production of the concrete components.

18. The method according to claim 14, wherein additively producing the concrete component comprises additively producing the concrete component with the composite concrete material by using a shotcrete process.

19. The method according to claim 16, wherein the method comprises setting up the manufacturing system for the additive production of concrete components using a shotcrete process.

Description

[0060] Preferred embodiments are explained by way of example with reference to the accompanying figures. They show:

[0061] FIG. 1: a schematic, three-dimensional view of an exemplary embodiment of a manufacturing system;

[0062] FIG. 2: a transparent view of the manufacturing system shown in FIG. 1;

[0063] FIG. 3: another schematic, three-dimensional view of an exemplary embodiment of a manufacturing system;

[0064] FIG. 4: a schematic, two-dimensional side view of the manufacturing system;

[0065] FIG. 5: a schematic representation of a process for the additive production of a concrete component; and

[0066] FIG. 6: a schematic view of a method for setting up a manufacturing system.

[0067] In the figures, identical or substantially functionally identical or similar elements are given the same reference signs.

[0068] FIG. 1 shows a manufacturing system 1 with a first manufacturing module 100, a second manufacturing module 200 and a third manufacturing module 300, whereby a peripheral module 400 is also provided. The first production module 100 has a first supply module 102 and a second supply module 104 shown in FIG. 2, through which a concrete component, in particular granules, can be introduced into the first production module 100. The second manufacturing module 200 includes a first sub-module 210, a second sub-module 220, and a third sub-module 230. The submodules 210, 220, 230 are configured to be vertically extendable. Each of the sub-modules 210, 220, 230 is a 20-foot container, and each includes a lifting system for raising the roofs and side walls of the sub-modules 210, 220, 230.

[0069] The interiors of the three modules 100, 200, 300 are shown in particular in FIG. 2. For manufacturing the concrete component with the concrete, the second manufacturing module 200 comprises a first handling unit 212. The first sub-module 210 further comprises a tool changing system 214 in which, for example, different spray nozzles for the handling unit 212 can be stored. Furthermore, the second manufacturing module 200 comprises a second handling unit 222, which is located in the second sub-module 220. The third sub-module 230, located between the first sub-module 210 and the second sub-module 220, includes a turntable 232. On the turntable 232, the concrete component is generated additively, in particular by means of a shotcrete process.

[0070] By means of the first supply module 102 and the second supply module 104, one or more concrete components can enter the first manufacturing module 100. Presently, these modules 102, 104 are formed as grids over which, for example, the concrete component can be dumped or can be provided, for example, in the form of a silo. From the supply modules 102, 104, the concrete component can reach a mixing unit.

[0071] Furthermore, the manufacturing system 1 comprises the third manufacturing module 300, which comprises feeding units 302 and a second metering unit 304. The charging units 302 are provided in particular for stocking additives, admixtures and binders for the concrete to be produced. The second metering unit 304, which is coupled to the charging units 302, can measure a weight or a volume or a quantity of the admixture or the binder and supply it to the underlying mixing unit 106 as required. In the mixing unit 106, these admixtures and binders are mixed with the concrete components, in particular granulates, supplied via the supply modules 102, 104.

[0072] The manufacturing system 1 further comprises a peripheral unit 400. The peripheral unit 400 comprises units for performing support processes. For example, the peripheral unit 400 may include an air pressure unit for providing compressed air. Furthermore, the peripheral unit 400 may comprise a wastewater treatment unit. Further, it may be preferred that the peripheral unit 400 comprises a power generator arranged and configured to provide electrical power to the manufacturing system. As a result, the manufacturing system can be operated autonomously and is particularly advantageously suitable for use close to the construction site. In addition, the peripheral unit 400 can comprise a reinforcement bending unit that is arranged and designed to form reinforcements, in particular reinforcing bars, in a component-specific manner.

[0073] FIG. 3 shows a further embodiment of the manufacturing system 1. In particular, the manufacturing system 1 differs from the manufacturing system described in the foregoing in that the first handling unit 212 and the second handling unit 222 are each arranged on a linear axis 214, 224. This arrangement allows the handling units 212, 222 to move in the direction of the linear axes 214, 224. As a result, the processing space is increased so that larger concrete components can be produced with the first handling unit 212. Furthermore, a linear table 234 is provided instead of the rotary table 232 described in the foregoing. The linear table 234 can be moved in the same direction as the handling units 212, 222. Thus, components can be moved into the manufacturing system 1 in a simple manner. In addition, even larger components can be manufactured by selective movement of the linear table 234.

[0074] FIG. 4 shows the interior of a first manufacturing module 100. A concrete component, in particular an aggregate granule, can pass through the supply modules 102, 104 onto the conveyor belts 130, 132. By means of the conveyor belts 130, 132, the concrete component is conveyed into the mixing unit 106. Vertically arranged above the mixing unit 106 is the third production module 300, which has the charging units 302. By means of the charging units 302 and the second metering unit 304, further concrete components, in particular binders and additives, are selectively brought into the mixing unit 106. In the mixing unit 106, the various concrete components are generally mixed together with water to produce a concrete. From the mixing unit 106, the concrete passes through a discharge hopper 108 towards a pumping unit 110. A conveyor unit 112 is arranged at the pumping unit 110, which couples the first manufacturing module 100 to the second manufacturing module 200.

[0075] Further, the first manufacturing module 100 includes a cleaning unit 114. The cleaning unit 114 is coupled to cleaning nozzles 116 in the mixing unit 106 and to cleaning nozzles 118 in the ejection hopper 108 and the pump unit 110. These are further coupled to a fresh water line 129. Fluid, in particular water, exiting the cleaning nozzles 116, 118 cleans the mixing unit 106, the ejection hopper 108 and the pump unit 110. In particular, when substantially no concrete to be processed is contained in these units, this cleaning is used. The water contaminated with cleaning particles, in particular concrete residues, is disposed of via a dirty water valve 120 and a dirty water pump 122. The disposal takes place via a gray water line 126, which passes a water treatment unit 124. From water treatment 124, the purified water returns to the purification system 114 via a white water line 128. From the purification system 114, the water can return to the purification cycle described previously.

[0076] FIG. 5 shows a method for additively producing a concrete component, in particular using a shotcrete process. In step 500, a first concrete component and/or a second concrete component is provided. This provision takes place in particular at a supply unit 102, 104 of a manufacturing system 1. This supply unit 102, 104 of the manufacturing system 1 can be formed, for example, by one, two or more silos or bag receiving devices.

[0077] In step 502, concrete is produced by mixing the first concrete component and the second concrete component. In particular, this mixing is performed in a mixing unit 106 of the manufacturing system 1. In step 504, a concrete component is additively manufactured using the previously generated concrete. This additive production of the concrete component is carried out in particular by means of a shotcrete process, in particular with a first handling unit 212.

[0078] Steps 500, 502, 504 may each comprise further steps, or further steps may take place between, before and/or after these steps, which will be described below.

[0079] In step 506, a first concrete component and a second concrete component are dispensed in a mix ratio specific to the component. In step 508, the concrete is then vibrated and/or pumped from the mixing unit to the handling system. In step 510, the concrete component is reworked, a reinforcement element is inserted and/or component components are inserted.

[0080] FIG. 6 shows a method for setting up a manufacturing system 1 for additive production of concrete components, in particular for carrying out a shotcrete process for additive production of concrete components. In step 600, a first manufacturing module 100 having a mixing unit 106 for generating a concrete based on concrete components is provided. In particular, the concrete is generated with the mixing unit by mixing a first concrete component and a second concrete component.

[0081] In step 602, a second manufacturing module 200 is provided with a first handling unit 212 for additive manufacturing a concrete component with the concrete. In particular, the first handling unit 212 is arranged and configured to produce a shotcrete component.

[0082] In step 604, the first manufacturing module 100 and the second manufacturing module 200 are coupled to each other, in particular such that the concrete generated in the mixing unit 106 is transferable to the first handling unit 212.

[0083] The manufacturing system 1 described in the foregoing has the particular advantage that it comprises a plurality of manufacturing modules 100, 200, 300, which are arranged in such a way that a modular structure of the manufacturing system 1 results in surprisingly high-quality components. This is made possible in particular by the clever selection of the distribution of the components provided in the manufacturing modules 100, 200, 300, in particular the mixing unit 106 and the handling units 212, 224.

[0084] In addition, the manufacturing system 1 enables on-site mixing of concrete component mixtures in that the manufacturing system 1 comprises the supply modules 102, 104 and the feeding units 302 with the second metering unit 304, so that a plurality of concrete components can be mixed together in a component-specific manner and thus no prefabricated concrete component mixtures are required.

[0085] The manufacturing system 1 further allows for flexible set-up in a manufacturing shop, on a construction site or in an area close to the construction site due to the setup with three separate manufacturing modules 100, 200, 300. The arrangement shown in the figures can be modified by adapting the interfaces so that the manufacturing system can be flexibly adapted.

REFERENCE LIST

[0086] 1 manufacturing system

[0087] 100 first manufacturing module

[0088] 102 first supply module

[0089] 104 second supply module

[0090] 106 mixing unit

[0091] 108 ejector hopper

[0092] 110 pump unit

[0093] 112 conveying unit

[0094] 114 cleaning unit

[0095] 116 cleaning nozzles

[0096] 118 cleaning nozzles

[0097] 120 dirty water valve

[0098] 122 dirty water pump

[0099] 124 water treatment

[0100] 126 gray water line

[0101] 128 white water pipe

[0102] 129 fresh water pipeline

[0103] 130 first conveyor belt

[0104] 132 second conveyor belt

[0105] 200 second production module

[0106] 210 first sub-module

[0107] 212 first handling unit

[0108] 214 tool changing system

[0109] 214 first linear axis

[0110] 220 second submodule

[0111] 222 second handling unit

[0112] 224 second linear axis

[0113] 230 third submodule

[0114] 232 rotary table

[0115] 234 linear table

[0116] 300 third manufacturing module

[0117] 302 feeding units

[0118] 304 second dosing unit

[0119] 400 peripheral module

[0120] 402 external rotary table