AU2021107506A4

AU2021107506A4 - Smart concrete trowel, curing and polishing robot

Info

Publication number: AU2021107506A4
Application number: AU2021107506A
Authority: AU
Inventors: Gholamreza Hashemi
Original assignee: Ahmadi Saber Doust Noushin
Current assignee: Ahmadi Saber Doust Noushin
Priority date: 2021-02-24
Filing date: 2021-08-25
Publication date: 2021-12-23
Anticipated expiration: 2029-08-25

Abstract

In the concrete construction industry, the processes of concrete troweling, polishing, and curing are carried out by traditional techniques and tools currently. Our aim is to eliminate these outdated methods and replaced them with progressive techniques and completely automatic processes. In fact, through this invention, all the required and necessary steps during preparing a concrete slab will carry on automatically and in a smart way. Through this Idea not only the concrete troweling and concrete polishing can be done so easily as fast as traditional machines in the minimum workforce and in a safer manner but also spraying the curing chemical compounds and polishing liquid at desired coverage level without aid, or human interference can be done automatically. Promoting productivity and efficiency by replacing the manual, labor-intensive, and high-risk processes with an automatic and remote-control robot, in higher quality and in a higher safety manner and in equal or even less timeframe and energy consumption rate are the main merits of our invention. r 0 U 0) U-

Description

r

U ) U- SMART CONCRETE TROWEL, CURING AND POLISHING ROBOT TECHNICAL FIELD

[0001] The invention refers broadly to techniques, tools, and instruments for use in the preparation of concrete, and in particular in the troweling, curing, and polishing of the concrete in intelligent and automatic ways.

BACKGROUND OF THE INVENTION

[0002] In the construction industry, one of the most important materials is concrete. And one of the most common applications of concrete is for floors, roads, and slabs. In creating the concrete slabs, once the concrete compacting is done, the slab would need to be gone over with a trowel. The next step is curing the concrete slab. Curing takes place immediately after concrete placing and involves maintaining desired moisture and temperature conditions, both at depth and near the surface, for extended periods of time. The proper curing process is vital to quality, durability, strength, and resistance to freezing and thawing. In the next step, the polishing process can be followed. Polished concrete is very durable, and it is very strong and won't be affected by heavy foot traffic. Damage to the flooring is pretty much impossible, and no scratches or chips can affect its aesthetics. The smooth, reflective surface of polished concrete invites a stunning array of options for coloring, scoring, and creating radial lines, grids, borders, and other designs.

[0003] In troweling and polishing the slab surface, based on the project size, three main tools are currently used: Hand tools, Walk-behind, and Riding Trowels/polishing machines. Moreover, there are various methods for concrete curing that most of them are require a huge amount of water, so they are costly.

[0004] Amongst the different curing methods, the curing compounds method is the most practical and widely used and is the most suitable alternative in water-scarce areas. Additionally, curing compounds are usually the most economical method for curing large areas. The curing compound way is ideal for regions directly exposed to sunlight, heavy winds, and other environmental influences. It can be used with advantages where wet curing is impossible.

[0005] The invention aims to save on time and cost of machinery used for concrete floor troweling, curing, and polishing, for which works, in state-of-art practice, at least three different machines are used. By itself, each one is expensive and requires storage space.

[0006] Currently, the processes of troweling, curing, and polishing are carried on by traditional techniques and tools. Our aim is to eliminate these outdated tools, combine and replaced them with progressive techniques through an intelligent machine.

SUMMARY OF INVENTION

[0007] Technical problems in using the current techniques in troweling and polishing stages: The riding trowels, especially polishing machines when used with the dust collector medium, requires adequate space and constant care and attention for maneuver and movement, so in small

areas, their handling is too challenging. Additionally, regardless of the troweling methods, laborers' walking on the fresh and soft concrete slab's surface with inadequate stiffness is inevitable. Lack of safety, labor falling in slab openings, and labor's obligation to use transport and safety equipment (suitable protective mask, proper eye protection, hearing protection, and protective gloves) are the main issues in using current power trowels and polishing machines. Hence, skilled workers and trained operators are necessary. Also, in most cases, there is the risk of losing control of machines. Moreover, handheld trowels and polishing tools cause pressure points on the palm of the hand and arteritis due to wrist bending. This could lead to an overuse injury to the hand or arm. To sum up, the mentioned processes would be time-consuming, labor intensive, hazardous, and expensive to get a satisfactory finished concrete surface.

[0008] The technical problems in current curing methods can be summarized. For example, most curing methods require a considerable amount of water, so they are costly and challenging when a particular location has water scarcity or insufficient water sources. On the other hand, in the plastic sheets curing method, the concrete strength will be reduced. The steam curing method cannot be applied to a large surface. In addition, curing by absorbing heat and sealed curing are rarely used techniques. The main opposing sides to using curing compound methods are Respiratory problems, caustic bums to the skin and eyes caused by toxic compound materials.

Moreover, in this method, complete coverage of the surface must be attained because even small pinholes in the membrane-forming curing compounds will increase the evaporation of moisture from the concrete. So uniform coverage is essential in this method. There are some similar issues when spraying the toxic and hazardous shining liquid on the polished concrete surface after the polishing process. Hence the skill required to apply the material correctly and uniformly.

[0009] Our solution to remove the current challenges in troweling, curing, and polishing procedures is their combination, using a Smart Robot. The mentioned steps can be done automatically or remotely control with the minimum time, energy consumption, and maximum accuracy only through one machine. The smart concrete Trowel, Curing, and Polishing robot is a combination of intelligent vacuum cleaners (but changed in function) with traditional concrete Trowel/Polishing machines. Hence, it does not need to be manually controlled by labor using its handles or by sitting on it. The robot has a number of different sensors, such as an anti-drop sensor, to navigate around the floor. It moves in a straight line until it senses an obstacle or a steep drop, such as stairs. It then turns in another direction based on the defined movement algorithm.

[0010] It has not only a remote optical function to allow the operator to guide the machine remotely, but also it can be automatically driven using an intelligent central computer, predicted cameras, and a Laser Direction system. The robot can be programmable and start the trowel, curing, and polishing steps, respectively, based on a specific schedule automatically and without aid or human interference. After uploading the plans of target concrete slabs through the USB ports, the robot can save the plans with all details (slab's openings coordination and surface obstacles, slab's edges and borders) within its central computer. The machine can move in a regular pattern without colliding with anything or falling over any edges using the cameras and the Laser Direction system. Plus, it can even recognize people and objects. The smart machine doesn't have the risk of labor failing in slab opening, and it doesn't need a trained operator for its control. It is also possible to monitor and control the robot remotely using a simple application on smartphones. (Bluetooth and Wi-Fi features).

[0011] With the robot, the curing compound technique as one of the most effective methods can be applied immediately after troweling process. It can be programmed to spray curing compound uniformly through a spraying nozzle at different spraying speeds (different discharge rates), with varied coverage angles and various time steps. The intelligent machine can automatically spray curing compounds without human interference, easily, quickly, and uniformly.

[0012] It is also predicted to change the Smart robot's function from Trowel to Polishing by replacing the trowel blades with the polishing disc. It is also predicted to add a detachable vacuum dust tank to the machine's back to pick up the heavy concrete slurry and other wet messes during the polishing procedure. Hence the contrary to traditional methods, the vacuum doesn't need to follow the polisher separately. After completing the polishing step, a shining liquid can be sprayed on polished surfaces uniformly at a high coverage speed through the high pressure spraying nozzles at the end of the smart robot. Since the mentioned polishing liquids and the curing compounds are chemical and toxic mixtures, the Smart machine's usage can effectively minimize their effects on the labor's health and the environment (less waste of chemical materials compared to traditional methods).

[0013] The advantages of the invention can be listed as below:

• It completely removes the interference of the laborers and becomes a fully smart and automatic or remote control. (Minimum Human Source Usage) • It is very useful when concrete is placed in inaccessible, difficult, or far-off places where wet curing is impossible. • Increases the efficiency of the finished Job by applying and spraying the shining and Polishing materials uniformly. • Reduces Safety Issues. • It is flexible in different spraying speeds of curing compounds and different time steps based on the project's conditions. • It is cost-saving, especially for extensive areas and with dry weather conditions. • It can be as fast as or even more than traditional machines with less involved labors, higher safety, and higher health level. • It is also possible to function, monitor, and control the machine using a simple smartphone application. (Bluetooth and Wi-Fi features) .

• It is a lightweight machine that quickly moves on the soft concrete surface during troweling step to create a smooth surface without sinking into it. In case which higher weight for leveling or polishing is required, an adjustable weight bar is predicted, which can be removable. • It has a less required Maneuver space, especially in the polishing step.

BRIEF DESCRIPTION OF DRAWINGS

[0014] Referring to the drawings:

[0015] FIG. 1 is a STATE-OF-ART drawing illustrating a smart robot, its application in a polishing robot equipped with adjustable weight disks, detachable dust storage, and a remote control panel.

[0016] FIG. 2 illustrates the same from different angles

[0017] FIG. 3 illustrates the same from the west side

[0018] FIG. 4 illustrates the same from the east side

[0019] FIG. 5 illustrates the same without a body shield

[0020] FIG. 6 illustrates the same from above without a body shield.

[0021] FIG. 7 illustrates the same without body shield, adjustable weight disks, and detachable dust storage.

[0022] FIG. 8 illustrates the same from a different angle.

[0023] FIG. 9 illustrates the same from under with body shield and detachable polish disk.

[0024] FIG. 10 illustrates the same from the west side, showing detach mechanism of dust storage

[0025] FIG. 11 illustrates the same from under, showing detach mechanism of polish disk and trowel blades.

[0026] FIG. 12 illustrates the same, its application as a trowel robot without weight disks and polish disk.

[0027] FIG. 13 illustrates the polish robot from under without a body shield

[0028] FIG. 14 illustrates the trowel robot from under without a body shield

[0029] FIG. 15 illustrates the polish robot from under and back

[0030] FIG. 16 illustrates the same on the west side with USB port, Wi-Fi and Bluetooth options, keyboard, and keypad LCD screen.

DESCRIPTION OF EMBODIMENTS

[0031] Attention is now turned to FIG. 1 and FIG. 2, which illustrates a STATE-OF-ART smart concrete polishing robot with related a remote-control panel, as a chosen example for its simplicity and commonality.

[0032] Attention is now turned to FIG. 3, which illustrates a west view of the polisher robot as a preferred embodiment of this invention. The robot has adjustable weight disks and bar 1, used to add the Smart machine's weight to allow the surface to be polished and shined after the Trowel and Curing process. The weight bar and its weights are detachable because the Smart robot must be at its lightest weight during the trowel and the Curing process in contrast to the polishing step. The dust storage 2 and its lid 3 are used to collect the dust transferred by suction/blower pipe 4 in it. There are two cameras equipped with a lighting torch, fixed in front 5 and back 6 of the robot. The Lighting Torch includes a set of torch and laser detection sensors to clear paths, detect the robot's precise position, and brighten surfaces while work is being done. In addition, in the back of the machine, predicted a spray nozzle 7, regarding the curing process and spraying the curing compound on the surface or spraying the polishing resin in its application as a polisher robot. There is a safety shield 8 for rotating trowel blades and polisher disk. In order to manage and transfer the data to the robot's computer, considered a data input interface 9. FIG. 4 illustrates a similar robot assembly from the east side, with fuel lid 10, curing compound lid 11, and disk/blades elevation regulator 12 to adjust the blades/polisher disk-level towards the concrete surface.

[0033] Robot's Wheels system: The robot's conceptual design shows that its wheel system is symmetrical, which implies that wheels are equally distributed on the structure. A back-roller steel Wheels, which are motor-driven, permits motion in only parallel directions and generates the torque needed to move the robot. The Rotatable front wheels steer the robot by actively and promptly switching the direction of the wheels. They are designed to facilitate the reverse and forward movement of the robot.

[0034] The state of the art of the concrete trowel robot is similar, using trowel blades but without dust storage and weight disks/bar. For simplicity, such a trowel robot is not illustrated here.

[0035] Attention is now turned to FIG. 5, which is an east section of the robot without a robot body shield. It illustrates the main mechanical parts of the robot, including the curing/polishing spray system. The specific fluid is contained within a flexible hose 15 fitted inside the pump 14, that is connected to related storage tank 13 and then spray on the concrete surface through nozzles 7. The Petrol engine 16, fuel tank 17, central computer 18, and the air blower vacuum shield, including the filters 19, are the others components of the robot.

[0036] As mentioned, both Curing and shining processes take precision and detail movement for different coverage levels and curing standards. The Curing Compound and polishing (shining) resin spray nozzles system located behind the Smart robot give a uniformly sprayed surface. Thanks to their pump, regulator, pressure gauge, etc., the simultaneous Nozzle's speed and pressure adjust is possible. Hence, the final provided surface is at much greater standards as well as higher safety levels than one created by manual laborers.

[0037] The Central Computer is responsible for providing a programable machine, smart navigation, stores, and analyses all the data as well as their processing and issuing all the related commands during the machine's operations. (Such as analysis of the Surface Plan, Directions, Curing Compound / Shining resin nozzle Settings, programing to start each process one after another, and more).

[0038] FIGS. 6 through 15 illustrate the 3D models of robots in different directions and angles. In Fig 8, the air blower vacuum engine 20 is indicated. The air blower vacuum is a device for switching from blower operation (activated in the robot's trowel function as a starting step for curing process) to a vacuum operation (activated in the polishing function of robot for suction of dust and redundant materials). Fig.11 illustrates the detachable polishing disk 21 and troweling blades 22.

[0039] Attention is now turned to FIG. 16, which illustrates the details of data manage interface 9. In order to input or transfer the data, such as coordination of surface map and the position of openings and edges, considered a data manage interface 9 including USB port and Bluetooth, or Wi-Fi options 23, LCD screen 24, and keypad 25.

[0040] Operation of Invention: During a reinforced concrete slab preparation, after the placed concrete is compacted with a mechanical vibrator, the operator will fill the robot's fuel tank 17 from its lid 10 and upload the plan of the slab with all details of openings, obstacles, and the edge of the sections into the Smart machine's the computer 18, by data interface pad 9, including the USB port, Bluetooth, or Wi-Fi options,23. and keypad 25.

[0041] Then the operator will place the smart robot at a start operation point on the surface of a fresh and soft concrete slab. To continue, the smart robot will regulate the trowel blade 22 elevations concerning the concrete surface by regulator 12, and the blower 20 blows the air by predicted pipe 4, and the blades rotate simultaneously. Then, the robot moving based on the uploaded plan and a predicted laser detection sensor 5 and 6 across the whole slab's surface according to a specific movement pattern and programmed algorithm. All the processes can carry on automatically, and the operator can monitor and control the machine's operation remotely through the predicted remote-control panel and mobile phone applications.

[0042] After troweling the whole concrete slab, it will automatically go back to the start point, and blades 22 will stop in this step. Then the operator fills its curing compound tank 13 from its lid 11, so it will be ready to start curing the surface. In this step, based on the desired coverage level and expected speed of spraying, the nozzles' 7 pressure will adjust automatically, and the curing compound fluid through pipe 15 will pump 14. It will spray onto the slab surface from the initial point to the end. After finishing the whole slab section's curing process, and after some days or hours (based on the project conditions and concrete properties), the Polishing step will start from the initial point.

[0043] In this stage, the operator will change the troweling blades with a polishing disk 21, placed them into protective case 8, install the detachable vacuum dust collector 2, to the back of the machine and adjust the robot's weight via removable disks/bar 1 based on the concrete hardness and desired polishing and shinning levels. Then, the remained curing compound liquid will discharge and replace it with water and the special resin in related tank 13 for the polishing procedure. The smart robot starts moving and polishing the surface using the polishing disk's rotation at a specified rotation speed in conjunction with sucking the created dust. The vacuum will pick up water and slurry from floors during the polishing procedure automatically through suction/blower pipe 4 and after filtration 19. Finally, the shining resin will spray on the polished surface through pipe 15, which will pump 14 and spray on the slab surface, according to defined coverage levels immediately and automatically.

CITATION LIST:

[0044] Non-Patent Literature:

•Design and Control of Concrete Mixtures - Scholar's Choice Edition, Portland Cement Association, Edition illustrated Publisher Creative Media Partners, LLC, 2015, ISBN 1294983954,9781294983958.

•Power Trowel with Poorly Placed Kill Switch Injures Worker, - Edited by Jessica Shapiro published © 2010 Penton Media, Inc. https://www.machinedesign.com/archive/article/21833207/power-trowel-with-poorly-placed kill-switch-injures-worker.

•Concrete Surface Treatment Chemicals Market Outlook - Authors: Kiran Pulidindi, Akshay Prakash, 2025, Published Date: April 2019 - 260 Pages - Report ID: GM13259 https://www.gminsights.com/industry-analysis/concrete-surface-treatment-chemicals-market.

•Guide for Curing of Portland Cement Concrete Pavements: Final Report, Chapter 4. The Final Curing Period, Publication Number: FHWA-RD-02-099, Date: January 2005. https://www.fhwa.dot.gov/publications/research/infrastructure/pavements/pccp/02099/chapt4.cf m.

•Princy K. P, Dr. Elson John, 2015, Study on the Effectiveness of Various Curing Methods on the Properties of Concrete, international journal of engineering research & technology (ijert) volume 04, issue 11 (November 2015), http://dx.doi.org/10.17577/ijertv4is110263

Claims

1. A smart concrete trowel, curing and polishing robot, compromising:

a self-driven concrete trowel machine applicable to a self-driven floor polishing machine through an air blower vacuum tool and a trowel blades/ polishing disk elevation regulator, attached to a curing compound and polishing (shining) resin spray nozzles system. and all connected to a central computer for robot programming, and data analyzing;

an obstacle detection system;

a remote-control panel; and

a transferring data system.

2. A smart robot, as in claim 1, wherein said applicable from concrete trowel to floor polishing robot, is adjustable by replacing said trowel blades with polishing disk, a detachable dust tank, a removable weights disks and said blower vacuum device.

3. A smart robot, as in claim 1, wherein said applicable as concrete curing robot, is adjustable by said a curing compound and polishing (shining) resin spray nozzles system. It can be programmed to spray curing compound uniformly through a spraying nozzle at different speeds (different discharge rates), with varied coverage angles and various time steps.

4. A smart robot, as in claim 1, wherein said, is self-driven concerning said obstacle detection system, including laser detection sensors and cameras, smartphone application, and said remote-control panel, connected to said central computer.

5. A smart robot, as in claim 1, wherein said, can be programmable with respect to said data transferring system including USB, Wi-Fi, and Bluetooth options thanks to said central computer.