EP3303710A1

EP3303710A1 - Method and apparatus for producing oblong support structures

Info

Publication number: EP3303710A1
Application number: EP16726109.8A
Authority: EP
Inventors: Anders Nielsen; Peter Dalgaard
Original assignee: Kd Pile Equipment AS
Current assignee: Kd Pile Equipment AS
Priority date: 2015-06-03
Filing date: 2016-06-01
Publication date: 2018-04-11
Also published as: WO2016193279A1

Abstract

The present invention relates to an apparatus for and a method of producing oblong supporting structures such as foundation piles. A a casting apparatus comprises a supply arrangement (11, 12, 13) for supplying composite material (6) to be distributed by the casting apparatus (1), a distribution unit (4) for distributing composite material (6) to groups (3_1-3_N) of oblong moulds (3_1a-3_Nn), which distribution unit (4) comprises a plurality of individually controllable outlet units (8_1-8_n) for distributing composite material (6) into said oblong moulds (3_1a-3_Nn), and a control arrangement (2) for controlling the supply of composite material (6) to said groups of oblong moulds, wherein said outlet units (8_1-8_n) are controllable by said control arrangement (2). The number of individually controllable outlet units (8_1-8_n) is larger than the number of moulds (3_1a-3_Nn) in a group (3_1-3_N) of moulds that are simultaneously supplied with composite material by said casting apparatus (1) during a casting session. A plurality of outlet units (8_1-8_n) for supplying composite material (6) to moulds in a group of moulds (3_1-3_N) during a casting session is selected, and a relative movement between said distribution unit (4) and a selected group of moulds (3_1-3_N) in a first movement direction (FMD) during supply of composite material (6) is provided during supply of composite material (6) to the group of moulds by means of selected outlet units (8_1-8_n).

Description

METHOD AND APPARATUS FOR PRODUCING OBLONG SUPPORT

STRUCTURES

The present invention relates to a method and an apparatus of producing oblong support structures. The invention moreover relates to a system comprising a casting apparatus and a plurality of oblong moulds for producing oblong support structures.

Background

Different solutions for producing oblong support structures such as piles, pillars and or the like for buildings are known. These oblong support structures are often made of a composite material in the form of reinforced concrete. The oblong support structures are among others used for foundation solutions and other supporting functions for e.g. buildings. For example foundation solutions are generally provided in different ways dependent on e.g. the composition and type, such as sand, clay and/or other earth types of support on and/or above which the building foundation is to be arranged. When the support is too soft to support the respective building by an ordinary foundation, oblong support structures in the form of foundation piles extending substantially vertically into the ground may be provided as a part of the building foundation to support the building.

Foundation piles of various types are known. Among such foundation piles are pre- casted foundation piles made from a composite material such as a concrete material. Such pre-casted foundation piles are casted at a remote location and then transported to the respective building location where they are dug and/or forced into the ground at the location of the building. After this, the remaining building is arranged to support on the foundation piles. Methods for producing pre-casted foundation piles are well known. Such methods comprises that the composite material such as a concrete material is provided into pile moulds arranged next to each other, while a relative motion between the moulds and the casting apparatus is provided in the longitudinal direction of the pile moulds. However such present methods may among other provide a low production capacity per time unit.

Moreover, apparatuses for producing oblong support structures such as pre-casted foundation piles may suffer from the drawback(s) of being resource demanding to operate, and/or demanding to maintain. The present invention provides a solution for producing oblong support structures such as pre-casted foundation piles which may e.g. solve one or more of the above mentioned issues.

The invention

The present invention relates to a method of producing oblong support structures such as foundation piles by means of a casting apparatus according to claim 1. The casting apparatus comprises:

a supply arrangement for supplying composite material to be distributed by the casting apparatus,

a distribution unit for distributing composite material to groups of oblong moulds, which distribution unit comprises a plurality of individually controllable outlet units for distributing composite material into said oblong moulds, and

a control arrangement for controlling the supply of composite material to said groups of oblong moulds, wherein said outlet units are controllable by said control arrangement,

wherein the number of individually controllable outlet units is larger than the number of moulds in a group of moulds that are simultaneously supplied with composite material by said casting apparatus during a casting session. The method preferably comprises the steps of: selecting a plurality of said outlet units for supplying composite material to moulds in a group of moulds during a casting session, providing a relative movement between said distribution unit and a selected group of moulds in a first movement direction during supply of composite material, which first movement direction extends the longitudinal direction of the moulds to be supplied with composite material, and supplying composite material to said group of moulds by means of said selected outlet units during said relative movement in said first movement direction.

As the number of individually controllable output units is larger than the number of moulds that are simultaneously supplied with composite material, it is possible to use different sizes of moulds with the same casting apparatus without providing a mutual movement between outlet units, or at least reducing the need of mutual movement between outlet units dependent on the mould type. Instead, the outlet units for supplying composite material to a mould may e.g. be selected based on their position at the distribution unit, and the mould type and/or position, thus allowing that only the outlet units arranged in the correct position to provide composite material to a specific mould is/are used for the respective mould in a mould group. Accordingly, this may provide a more reliable and less maintenance demanding apparatus, as there may occur fewer or no problems due to e.g. dried composite material such as a concrete material hindering movement of movable parts of the apparatus.

The composite material is preferably a concrete material supplied by the outlet units in a liquid", uncured state, and the composite material, when supplied to the moulds, floats and distributes to fill the mould cavity to which it is supplied, and thereafter the material cures.

The method may in in advantageous aspects of the invention comprise that a reinforcement such as a metal structure made from e.g. metal wires, metal rods and/or metal plates are arranged in the moulds before the casting session so that the reinforcement is substantially embedded in the composite material. It is generally to be understood that reinforcements such as metal wires or the like may be arranged in the moulds before a casting session is initiated. Also, the casting capacity of the apparatus per time unit may be increased by the present invention as a more dynamic and individually adjustable casting apparatus and method is provided for casting oblong support structures such as foundation piles. Moreover, the present invention may provide more uniform and reliable oblong support structures as the apparatus may provide adjustment possibilities due to the outlet unit setup and the resulting control possibilities.

The present invention has shown to be suitable for casting of different types and/or sizes of oblong, supporting structures in the form of e.g. foundation piles made from reinforced concrete, where the casting apparatus is to be used for a plurality of different types and/or sizes of moulds. Such moulds may be located in large production facilities comprising e.g. at least ten such as at least twenty or even more such as at least thirty groups of moulds such as foundation pile moulds, where each group may comprise at least four such as at least five, e.g. at least six such as at least seven or even more moulds per group.

By the present solution, a large amount of oblong support structures such as foundation piles of different sizes may be casted each day and then cure until e.g. the next day where the cured oblong structures are removed from the moulds and casting of new structures can then be initiated by the casting apparatus in the same moulds.

The oblong support structures are in preferred aspects of the invention pre-casted foundation piles made from a concrete material (preferably reinforced by a metal reinforcement made from metal wires, metal rods and/or the like which is embedded in the concrete material). These are produced in moulds according to one or more aspects of the present invention and subsequently cured in the moulds before they are removed from the moulds and transported to a location to be driven and/or dug vertically into the ground as a part of a building foundation. In preferred aspects of the invention, a group of moulds for receiving composite material simultaneously by the distribution unit comprises a plurality of moulds.

In other embodiments of the invention, the method may be also be utilized for fast and efficiently producing other types of oblong reinforced concrete structures such as supporting pillars for building support, e.g. bearers, pillars and/or lintels for buildings, bridges, roads, and/or the like.

It is to be understood that the oblong moulds may also be referred to as "pile moulds", "moulds" and/or the like in this document, but that the moulds naturally may be utilized for and adapted for producing oblong support piles such as foundation piles, pillars, bearers and/or the like for building structures such as bridges, houses, factories, high rise buildings.

It is moreover to be understood that the moulds groups may also be referred to as "pile mould groups", "group(s) of pile moulds" and/or the line in this document, but that the mould naturally may be utilized for producing oblong support structures for buildings such as foundation piles, pillars, bearers and/or the like.

The casting session may also be referred to as e.g. a "pile casting session" in this document.

Generally, it is understood that said control arrangement may comprise a computer arrangement including a computer processor and a data storage comprising a computer program configured to facilitate control and selection of said outlet units and preferably said relative motion between the distribution unit and said moulds. In a preferred aspect of the invention, said plurality of outlet units are distributed at said distribution unit in a direction transverse to said first movement direction.

This provides that the outlet units may thus be moved in the first movement direction while supplying composite material to a plurality of mould groups arranged side by side in parallel.

This may e.g. be provided by two or more outlet unit rows extending in a direction substantially perpendicular to (or at least having a component in) the longitudinal direction of the moulds to be supplied with composite material.

In an advantageous aspect of the present invention, said composite material is supplied substantially continuously during said relative movement to the respective moulds in a mould group from a first end of the moulds to the opposite end of said moulds during said casting session by means of the selected outlet units and drive means controlled by said control arrangement.

This may e.g. provide a fast, automated and reliable casting process which may increase the production capacity and/or enhance the quality and reliability of the produced oblong structures such as foundation piles. The control arrangement preferably controls this process by controlling the outlet units and the drive means.

In preferred aspects of the invention, a plurality of outlet units are selected for supplying composite material to the same mould during a casting session.

Accordingly, it is e.g. possible in a simple way to reduce or increase the amount of composite material supplied at each mould dependent on the mould size, by controlling the amount of control units used for supply the material to the respective mould by opening or closing the outlet unit(s). Moreover, it may provide a fast and yet easily adaptable supply of composite material dependent of the type of mould e.g. without needing to have different sizes/types of outlet units dependent on the mould. Moreover, it may be possible to provide a relative movement between moulds and casting unit in the longitudinal direction of the group of moulds with an increased speed.

For example, two outlet units such as three outlet units, e.g. four outlet units such as five outlet units may be utilized for supplying composite material to the same mould in said group of moulds.

In advantageous aspects of the invention, the selection of outlet units comprises assigning said plurality of outlet units to different outlet sub-groups, wherein the outlet sub-groups simultaneously supply composite material to different moulds in a mould group, wherein the number of sub-groups correspond to the number of oblong moulds in the mould group to receive composite material simultaneously during said casting session, and wherein the total number of outlet units assigned to said outlet sub-groups preferably may be higher than the number of moulds to be supplied with said composite material during the casting session. Hereby is e.g. a dynamic and reliable solution provided where the apparatus can fast and efficiently be adapted to provide composite material to different mould types such as different mould sizes.

The selection may generally in preferred aspects of the invention comprise that the number of outlet units used to supply material during a casting session represents a subset of the overall number of outlet units of the distribution unit.

In advantageous aspects of the invention, the casting apparatus 1) comprises a level sensor arrangement, which level sensor arrangement detects the level of composite material supplied to said moulds by the outlet units, e.g. by detecting the composite material surface in one or more moulds, and wherein the supply of composite material by said selected outlet units is controlled by said control arrangement based on data input from the level sensor arrangement.

This may e.g. provide a reliable and efficient way of assuring that the correct amount of composite material has been supplied no matter what type and/or size of mould that has been provided with the composite material. Moreover, it may be assured that the composite material has been distributed evenly in a mould, e.g. as the sensor arrangement may be movable together with the distribution unit during a casting session. The level detection may in aspects also be utilized for determining the amount of composite material that is left in a buffer of the apparatus as volume information of a mould may be stored in the apparatus, and the level may thus be utilized for determining the amount of composite material supplied.

Advantageously, said level sensor arrangement may in aspects of the invention comprise a plurality of level sensors distributed in a direction transverse to said first movement direction, and the control of supply of composite material to each mould in a group may preferably be provided individually for each mould during a casting session based on input from one or more of said level sensors detecting the composite material level in the respective mould.

This may e.g. help to provide a more even result of oblong structures.

The distribution unit may in aspects of the invention provide at least two movements in the first movement direction during a casting session, including a first movement where the moulds are initially supplied with composite material, and a second, subsequent movement where further composite material is supplied to the same moulds, preferably based on data input from said level sensor arrangement so as comply with a predefined level threshold. This may assure e.g. an even distribution of composite material and thus a more even result of oblong structures produced by the apparatus. It may also help to increase the production speed. In preferred aspects of the invention, said distribution unit may be displaced by drive means in a second movement direction substantially transverse to said first movement direction so as to supply composite material to one or more further groups of moulds during further casting sessions. This may e.g. be provided by a one or more support structures such as one or more beams extending horizontally, and wherein the distribution unit is movably arranged at said one or more structures, e.g. by means of a rail/wheel arrangement.

In advantageous aspects of the invention, the control arrangement moves the distribution unit in the second direction to a mould group position of a selected group of moulds before providing composite material to said selected mould group, wherein said position preferably is predetermined based on a position stored in a data memory of said casting unit. This may e.g. be provided by having position sensors arranged in the second movement direction, by stepper motors and/or the like.

In advantageous aspects of the invention, the selection of a plurality of outlet units comprises that a subset of said plurality of outlet units is selected for supplying composite material to a group of moulds, wherein said selection preferably is based on a mould type selected among a set of different predefined mould types, preferably by means a user interface.

This provides that some of the total amount of outlet units is left unused during a casting session, while these may be used in another casting session for another mould group. Accordingly, it may not be needed to move the outlet units in relation to each other, as instead of moving the outlets, different outlets are selected. This may provide a dynamic and yet efficient and reliable casting solution The identifying/selection of a mould/mould type may e.g. comprise that a user by means of a user interface select a mould type, e.g. based on the size of the moulds. For example, a group of moulds to be simultaneous supplied with composite material may be selected based on width and height dimensions. For example, a group of moulds, e.g. foundation pile moulds, may be selected based on if they are configured for moulding oblong structures having a 20cm x 20cm cross section, 27cm x 27cm cross section and/or 35cm x 35cm cross section respectively.

Based thereon, the control unit selects which of the outlet units that should be used for supplying the respective mould with composite material. This often provides that some of the outlet units are deselected and not used for supplying composite material during a casting session as the width of the moulds varies, while the overall width of a mould group to be simultaneous supplied with composite material is the same for groups of pile moulds of different types and with different width.

Advantageously, said control arrangement may in aspects of the invention adjust one or more operational parameters to a predefined setting based on the identified mould type, wherein said operational parameters comprises one or more of the following Movement speed in said first movement direction,

- the position and/or orientation of a plurality of level sensors of a level sensor arrangement of said apparatus.

This may e.g. help to provide an efficient automated casting solution, where composite material is provided in a reliable way dependent on the mould size(s) and positions. For example, a larger mould with a larger volume or at least a larger width and height may need a reduced relative movement speed of the distribution unit and/or mould(s) in the first direction compared to smaller moulds having a less volume or at least reduced width and height. Also, during selection of different mould types, this may call for an adjustment of the level sensors, e.g. by drive means such as electric motors or linear actuators that are adjusted by the control

arrangement based on the mould type. The apparatus may in preferred aspects of the invention be configured for providing composite material to a plurality of groups of moulds by means of said control arrangement by moving said distribution unit to different position, wherein each group of moulds comprises a plurality of moulds arranged in parallel, wherein said groups of moulds comprises moulds of different sizes, and wherein the width of the different groups of moulds to be supplied with composite material preferably is substantially identical.

The moulds, such as foundation pile moulds, to be simultaneous supplied with composite material are in preferred aspects of the invention often parallel arranged in groups of moulds where the moulds are separated by partition walls/separator walls. This has shown to e.g. be a reliable and fast method of producing oblong structures.

It is generally to be understood that the apparatus in aspects of the invention may be configured in order to provide composite material to a group of moulds having different sizes during a casting session, or the group may comprise moulds of substantially the same size during a casting session. In respect to thus, it is understood that the size of the moulds may vary by the width of the moulds being different in a group of moulds to be supplied with material during a casting session.

Moreover, it is generally understood that the apparatus in aspects of the invention may define a group of moulds based on a plurality of casting templates, preferably stored in a data storage of a control arrangement of the apparatus. Each casting template may thus comprise information about which outlet units, such as outlet unit sub-groups, that should be used for providing composite material to the respective moulds of a mould group, and thus different combinations of outlet units may be used for providing composite material dependent on the selected casting template during different casting sessions. Preferably, said plurality of outlet units may in aspects of the invention be arranged in a substantially fixed position relative to each other at said distribution unit, e.g. by being supported by a frame structure of the distribution unit. This may provide a more compact, simple and/or reliable distribution unit. Thereby, no relative motion between the outlet units in at least an outlet unit row is needed to adapt to different moulds, which may provide an apparatus where less maintenance is needed and thus an apparatus which is more cost efficient and/or which provides a higher production capacity may be obtained.

Said plurality of outlet units of the distribution unit may in aspects of the invention comprise at least two outlet unit rows each comprising a plurality of outlet units, where each outlet unit row extend in a direction transverse to said first movement direction of said distribution unit.

Advantageously, said plurality of outlet units may comprise a first outlet unit row and a second outlet unit row, each outlet unit row comprising a plurality of outlet units extending in a direction transverse to the longitudinal direction of said moulds. In an advantageous aspect of the invention, said distribution unit comprises at least ten such as at least twenty, e.g. at least at least thirty, such as at least fifty, for example around sixty-eighty and preferably no more than hundred outlet units.

The row arrangement of the outlet units e.g. provides a distribution unit which is compact and yet provides advantageous adjustment possibilities of the composite material supply. For example, one, two or even more outlet units from each outlet unit row may be used to supply material to the same mould during a casting session whereby an increased material supply is provided so that the movement speed in the first direction may be increased. However, in other situations it may be more advantageous to provide a solution where less outlet units are used to e.g. provide a more controlled flow of composite material, e.g. during a supplementing filling supply of composite material. The said outlet units may in aspects of the invention advantageously be distributed over a distance substantially corresponding to the width of a mould group to be supplied with composite material simultaneously during a casting session.

In preferred aspects of the present invention, casting the apparatus comprises a plurality of casting templates, preferably stored in a data storage of the control arrangement, wherein each casting template comprises information of which outlet units, such as outlet unit sub-groups, that should be used for providing composite material to the respective moulds of a mould group, and wherein different combinations of outlet units are used for providing composite material dependent on the selected casting template.

This provides a fast and efficient change between different mould types and/or sizes as e.g. a user may select a type of mould by a user interface and the control arrangement may then select predefined, suitable outlet units, movement speed, positions of level sensors and/or the like based on a casting template identified based on the user selection. Moreover it may provide an easy adaption of the apparatus to new mould types and/or mould groups.

The supply arrangement may in aspects of the invention comprise a first material buffer arranged so as to store supply composite material to said outlet units of the distribution unit. This may help to provide a more even supply of composite material and thus an enhanced and more reliable production of oblong structures such as reinforced concrete piles, pillars and/or the like.

The said first material buffer is preferably arranged to move in a second movement direction transverse to said first movement direction, preferably simultaneously with said distribution unit. The supply arrangement may in advantageous aspects of the invention comprises a buffer, such as a second material buffer, configured to travel between a delivery location and a receiving location, wherein said material buffer receives composite material at said receiving location, and delivers the received composite material at the delivery location, wherein said delivery location delivery location preferably is determined by the position of the distribution unit, and wherein the second material buffer delivers the received composite material to said distribution unit.

This may further help to ensure a reliable, consistent and fast automated production of the oblong structures in a plurality of mould groups as a continuous supply may hereby be provided. The second material buffer is in preferred aspects of the invention preferably movable by the control arrangement independently of the movement of the first material buffer.

Said moulds have in an aspect of the invention a length from a first end wall to a second end wall of the moulds, such as foundation moulds, which length is between 5 and 25 meters such as e.g. between 13-17 meters, and wherein said length substantially corresponds to the length that said distribution unit travels between the end walls in said first movement direction in order to supply said composite material during a casting session.

In aspects of the invention, the width of each of said moulds in a mould group is between 100mm and 1000mm such as between 150mm and 700mm, e.g. between about 200mm and 400mm including both endpoints.

In advantageous aspects of the invention, different combinations of outlet units may be selected dependent on the width of the moulds of the mould groups. The invention moreover relates to a casting apparatus for producing oblong support structures, such as foundation piles, which casting apparatus comprises:

a control arrangement configured for controlling the supply of composite material to groups of moulds, wherein said outlet units are individually controllable by means of said control arrangement,

wherein said apparatus comprises selection means configured for selecting outlet units of said distribution unit for supplying composite material to moulds in a group of moulds during a casting session,

wherein said selection means are configured to select a subset of said plurality of individually controllable outlet units for supplying composite material to said group of pile moulds,

which subset of individually controllable outlet units comprises a plurality of said outlet units, and

wherein said apparatus is configured for providing a relative movement between said distribution unit and a selected group of oblong moulds in a first movement direction during supply of composite material to a selected group of moulds by means of said selected subset of outlet units.

In an aspect of said casting apparatus according to aspects of the invention said selection of outlet units comprises assigning said plurality of outlet units of said subset to different outlet sub-groups, wherein the outlet sub-groups are configured for simultaneously supplying composite material to different moulds. In an aspect of said casting apparatus, said plurality of outlet units may in aspects of the invention be distributed at said distribution unit in a direction transverse to said first movement direction.

In an aspect of said casting apparatus according to aspects of the invention, said apparatus may be configured so that composite material is supplied substantially continuously to the respective moulds in a group during said relative movement in the first movement direction from a first end of moulds to the opposite end of said moulds during a casting session.

In preferred aspects of the casting apparatus, the apparatus is configured so that a plurality of outlet units of said subset are selected for supplying composite material to the same mould, preferably by being member of the same sub-group.

In preferred aspects of the casting apparatus, said casting apparatus comprises a level sensor arrangement, which level sensor arrangement is configured to detect the level of composite material supplied to said moulds by the outlet units, e.g. by detecting the composite material surface in one or more moulds, and wherein the supply of composite material by said outlet units is configured to be controlled by said control arrangement based on data input from said level sensor arrangement.

The control of composite material based on the level sensor arrangement may e.g. comprise start and/or stop of supply of composite material, and/or adjustment of supplied amount by varying the number of selected outlet units used.

In preferred aspects of the casting apparatus according to aspects of the invention, said distribution unit is configured to be displaced by drive means in a second movement direction substantially transverse to said first movement direction so as to supply composite material to one or more further groups of moulds. The drive means may in aspects comprise one or more electric motors, one or more linear actuators and/or the like.

In advantageous aspects of the casting apparatus according to aspects of the invention, said selecting of one or more of said outlet units may comprise identifying a mould type among a set of different predefined mould types, preferably by a user interface, and wherein said control arrangement is configured to provide said selection of a subgroup of outlet units based on the identified mould type. In preferred aspects of the casting apparatus according to aspects of the invention, said plurality of outlet units are arranged in a substantially fixed position relative to each other at the distribution unit.

In preferred aspects of the casting apparatus, said plurality of outlet units of said distribution unit comprises at least two outlet unit rows each comprising a plurality of outlet units, where each outlet unit row extend in a direction transverse to said first movement direction of said distribution unit.

There may in aspects of the invention be at least two, three or four or even more outlet unit rows each extending in a direction transverse such as substantially perpendicular to the first movement direction. The outlet unit rows may e.g. be arranged substantially in parallel.

The casting apparatus may in aspects of the invention be configured so that said selection of said subset of outlet units is configured to be provided based on a plurality of casting templates stored in a data storage of said control arrangement.

In aspects of the casting apparatus each of said casting templates may comprise information of which outlet units, such as outlet unit sub-groups, that should be used for providing composite material to the respective moulds of a mould group, and wherein said apparatus is configured so that different combinations of outlet units are used for providing composite material during a casting session dependent on the selected casting template.

Advantageously, in aspects of said casting apparatus, said supply arrangement at least comprises a first material buffer arranged to supply composite material to said outlet units of the distribution unit.

Advantageously, in aspects of the invention, the casting apparatus may comprise one or more support structures such as one or more beams extending horizontally, and wherein the distribution unit is movably arranged at said one or more structures, e.g. by means of rails, so as to provide a movement of said distribution unit in a second movement direction transverse to said first movement direction.

The casting apparatus may also or alternatively comprise further composite material buffers such as a second and/or a third buffer as described in this document.

In aspects of the casting apparatus, the casting apparatus is configured to operate in according to the method of one or more of claims 1-22. The invention additionally relates to a system comprising a casting apparatus and a plurality oblong moulds for producing oblong support structures, such as foundation piles, wherein the casting apparatus is a casting apparatus according to any of claims 23-37, and wherein said plurality oblong moulds of said system comprises groups of oblong moulds, each group comprising at least four such as at least five, e.g. at least six such as at least seven moulds in a group, and/or wherein said moulds are located in a production facility comprising at least ten, for example as at least twenty, such as at least thirty groups of moulds such as foundation pile moulds.

Figures

Aspects of the present disclosure will be described in the following with reference to the figures in which: : Discloses an embodiment of a a distribution unit of a casting apparatus according to embodiments of the invention,

: discloses an embodiment of the control of a casting apparatus according to embodiments of the invention,

c : discloses molds in mold groups according to embodiments of the invention,

: illustrates embodiments of a control arrangement 2 according to embodiments of the invention,

: illustrates schematically an embodiment of the invention where a level sensor arrangement is provided,

: illustrates a casting apparatus according to embodiments of the invention.

: illustrates a flowchart according to embodiments of the invention : illustrates a further flowchart according to embodiments of the invention

b : illustrates embodiments of the invention comprising casting templates : illustrates an embodiment of the invention, wherein a distribution unit comprises a plurality of outlet unit rows

: illustrates an embodiment of a control device, and

: illustrates further embodiments of a casting apparatus according to embodiments of the invention.

Detailed description

Fig. 1 discloses schematically a distribution unit 4 of a casting apparatus 1 according to embodiments of the invention. Further embodiments of the casting apparatus 1 is described in more details later on.

The distribution unit 4 comprises a plurality of individually controllable outlet units 8_l-8_n for distributing composite material (6) into a group of oblong moulds 3 1 a- 3_Nn, in this embodiment the group of moulds comprises eight moulds.

The composite material is preferably a concrete material that is supplied to the moulds and subsequently dried in the moulds.

As can be seen from the present embodiment, the number of individually controllable outlet units 8_l-8_n is larger than the number of pile moulds in a group 3 1 of moulds that are simultaneously supplied with composite material in a liquid state. Accordingly, the distribution unit 4 provides the possibility of selecting one or more of the outlet units (8_l-8_n) for supplying composite material to each mould in the group 3 1 of moulds (3_la-3_ln) simultaneously during a casting session.

In the present example, the outlet units 8 1 and 8 2 are used to supply composite material to the first mould 3 1 a, the outlet units 8 5 and 8 6 are used to supply composite material to the second mould 3_lb, the outlet units 8 9 and 8 10 are used to supply composite material to the pile mould 3 1 c and so on.

Accordingly, a number of outlet units, in this case among others the outlet units 8 3, 8 4, 8 7, 8 8 and so on are left unused during the supply of composite material to the illustrated mould group 3 1 due to the partition walls 7 separating the parallel arranged moulds 3_la-3_ln of the pile mould group. The plurality of outlet units 8_l-8_n are thus assigned to different outlet sub-groups that simultaneously supply composite material to different moulds. In this case, the outlet units 8 1 and 8 2 may be considered as assigned to a first outlet subgroup, as they are to be used for supplying composite material to the same mould (i.e. in this case pile mould 3 1 a). The outlet units 8 5 and 8 6 are assigned to a second outlet subgroup as they are to be used for supplying composite material to the same mould (i.e. in this case pile mould 3_lb), and so on.

The number of outlet sub-groups for supplying composite material, in this case eight sub-groups, may preferably correspond to the number of molds 3_la-3_ln to receive composite material simultaneously.

Accordingly, as the illustrated distribution unit 4 comprises thirty outlet units, the total number of outlet units 8_l-8_n is higher the number (in this case eight) of pile molds to be supplied with composite material 6.

Accordingly, in embodiments of the invention, the number of outlet units for supplying composite material to the pile moulds 3_la-3_ln during a casting session may be at least two times such as at least three times, e.g. at least four times such as at least five times higher than the number of moulds 3_la-3_ln in a mould group 3 1 to be supplied simultaneously with the composite material.

The moulds thus provide a cavity in which an oblong structure such as a foundation pile can be shaped.

In the present example the number (subset) of outlet units for supplying the composite material is sixteen, and as there are eight moulds 3_la-3_ln in the present mould group 3 1, the number (sixteen) of outlet units for supplying the composite material is twice as high as the number of pile moulds (eight). Fourteen outlet units are in the present example left unused and thus not part of the subset. In preferred embodiments of the invention, the outlet units 8_l-8_n may e.g.

comprise fluid controllable valves such as controllable by means of pneumatics, but in other embodiments of the invention, they may include electric control means such as electric motors for opening and closing the outlet units.

The composite material 6 is thus supplied by the distribution unit 4 to the group 3 1 of pile moulds 3_la-3_ln by means of the selected outlet units 8_l-8_n during a relative movement in a first movement direction FMD that extends the longitudinal direction LD of the pile moulds 3_la-3_ln to be supplied with composite material 6. Embodiments hereof are described in more details later on.

The plurality of outlet units 8_l-8_n are, as illustrated in preferred embodiments of the invention arranged in a substantially fixed position relative to each other at the distribution unit, e.g. by being attached to a frame structure of the distribution unit 4 by fastening means such as screws, mountings, welding and/or the like.

Fig. 2 illustrates an embodiment of the invention wherein the distribution unit 4 of the casting apparatus 1 is moved between different groups 3 1-3 N of moulds 3 1 a- 3_Nn between different casting sessions.

In this case, three mould groups 3 1-3 N are illustrated, i.e. a first mould group 3 1, a second mould group 3 2 and the third mould group 3_N. Each mould group comprises a plurality of moulds. It is naturally to be understood that even more mould groups may be arranged besides each other, as may a plurality of mould groups be arranged substantially end to end and/or the like. For example the casting apparatus 1 may thus in embodiments of the invention be arranged so as to supply composite material to e.g. twenty such as forty, e.g. sixty or even more mould groups (not illustrated in fig. 2). However, the first mould group 3 1 comprises a first number of moulds 3_la-3_n, in this case eight moulds, the second mould group 3 2 comprises a second number of moulds 3_2a-3_2n, in this case seven moulds, and the third mould group may comprise a further number of moulds, e.g. six moulds. The number of moulds in a group 3_1-3_N of moulds preferably varies dependent on the width (W2 , see fig. 3a) of a mould. The width W 1 1 -WI N of a group of moulds may thus be substantially the same: W1_1=W1_2=W1_N, but the number of moulds in each group 3_1-3_N may vary dependent on the width of the moulds in each of the groups 3 1-3 N. The distribution unit 4 is thus moved between the different groups 3 1-3 N of moulds. As the number of moulds in the mould groups 3 1-3 N may vary, different outlet units 8_l-8_n are selected dependent on the mould type. The outlet units may thus be selected based on the type of mould to be supplied with composite material, e.g. dependent on the width of the moulds in a mould group.

As can be seen from fig. 2, different combinations of outlet units are used for supplying composite material to the different mould groups. When supplying composite material to the first mould group 3 1, 8x2 outlet units are used to supply composite material to the moulds 3_la-3_ln, and fourteen outlet units 8 1 are left unused as illustrated in figs. 1 and 2.

When supplying composite material to the second mould group 3 2, 7x2 outlet units are used to supply composite material to the moulds 3_2a-3_2n, and 1 sixteen outlet units 8_l-8_n are left unused. It is thus understood that e.g. the number of outlet units used, and/or which outlet units 8_l-8_n that are used may depend on the type of moulds in a mould group 3 1-3 N.

In the present example, three casting sessions are used, one for each mould group 3_l-3_n. Accordingly, different subsets of the outlet units 8_l-8_n may be used for different casting sessions, and thus both the number of how many outlet units 8_l-8_n that are used for moulding and how many that are left unused during a casting session, and/or which outlet units 8_l-8_n that are used in the different casting sessions may be varied, e.g. in accordance with a stored data in a data storage of the apparatus 1, such as a casting template.

As can be seen from fig. 2, the same outlet units that were used for leftmost mould 3 1 a in the first mould group 3 1 may be used for leftmost mould 3_2a in the second mould group 3 2. But for the next mould 3_2b in the second mould group 3 2, an outlet unit (in this case outlet unit no. seven from the left) that was left unused during the moulding process in the mould 3_lb next to the leftmost group 3 1 is now used for the moulding process in the mould 3_2b while another outlet unit (in this case outlet unit no. five from the left) that was used during moulding in the mould 3_lb is left unused.

Fig. 2 illustrates a further embodiment of the invention wherein the distribution unit 4 is movably arranged to be displaced by drive means in a second movement direction SMD substantially transverse to the longitudinal direction of the moulds 3_la-3_ln. This movement is preferably provided between casting sessions to provide composite material to the respective mould groups 3 1-3 N.

Preferably, the second movement direction SMB is substantially perpendicular to the first movement direction FMD in the longitudinal direction LD of the moulds, see e.g. fig. 3c and fig. 12.

During the first casting session, the distribution unit 4 supplies composite material to the first group of moulds 3 1. Then the casting unit is moved (see arrow SMD) in a direction transverse to the longitudinal direction of the moulds to the next group of moulds 3 2 where a new, second casting session is initiated. Between the two casting sessions, a new selection of outlet units 8a-8n may be provided in order to adapt the pile casting to a new type/size of pile moulds. This may in embodiments of the invention be provided by e.g. selecting a new casting template between a plurality of casting templates, which may e.g. include selection of one or more outlet units different from the outlet units used for providing the composite material 6 to the first group of pile moulds 3 1. This is described in more details later on.

The distribution unit 4 is preferably connected to a frame structure 14 which is movably arranged to facilitate the movement in the direction SMD transverse to the longitudinal direction of the moulds by drive means such as an electric motor.

In alternative embodiments of the invention, a new group of moulds may be moved to be arranged below the distribution unit 4 between different casting sessions, and a group of moulds that has been filled with composite material may thus be moved to another position, e.g. on rails, wheels and/or the like.

The distribution unit 4 may in preferred embodiments of the invention comprises a first buffer container 13 having a cavity/storage space for containing composite material 6 to be supplied to the moulds by the outlet units 8_l-8_n. The buffer container 13 is arranged above the outlet units so that the composite material is supplied from the buffer container 13, through the outlet units 8 1 - 8_n when the outlet units are opened, and into the moulds. The first buffer container 13 is considered as a part of the supply arrangement for supplying composite material to the outlet units 8_l-8_n, and is in preferred embodiments of the invention movable together with the outlet units 8_l-8_n.

Fig. 3a illustrates schematically a preferred embodiment of a mould group 3 1 comprising a plurality of pile moulds 3_l-3_n, seen in a cross sectional view, in this a pile mould group for e.g. foundation piles. The moulds 3_l-3_n are parallel arranged and divided by partition walls 7, thereby providing a pile mould group structure 20 having an overall width Wl l configured so that the distribution unit 4 (not illustrated in fig. 3) may provide the composite material to all of the moulds 3_l-3_ln simultaneously during a casting session. The width Wl l may thus correspond to at least the sum of the widths W2 of the moulds plus the sum of the widths W3 of the partition walls 7 and side walls.

It is understood that in embodiments of the invention the depth D of the moulds 3_la-3_ln may be varied dependent on the mould type, as may the width W2, e.g. as illustrated in fig. 2, but the overall width Wi n of the respective mould group structure 20 is preferably substantially the same or in embodiments of the invention less than the width over which the outlet units 8_l-8_n of the distribution unit 4 extend in the direction transverse to the longitudinal direction of the moulds, so as to facilitate that the distribution unit can provide the composite material 6 to the mould group simultaneously.

The pile moulds may thus in preferred embodiments of the invention have substantially the same support structure 21 for the moulds 3_la-3_ln.

Fig. 3b illustrates the pile mould group 3 1 a seen from above. The mould group 3 1 extends in the longitudinal direction LD of the moulds 3_la-3_ln which are arranged in parallel next to each other. Each mould is end ended by an end stop/end wall 10. Hence the partition walls 7 (and e.g. side walls 19) encloses each their cavity 18_a - 18_n for receiving the composite material from the distribution unit 4. In embodiments of the invention, one or more of the end stops/end walls 10 may be movable so as to provide that the length of the moulds can be adjusted over time. In other embodiments of the invention, one or more of the end stops may be fixed without adjustment possibilities. In embodiments of the invention wherein the moulds are used for foundation piles, the mould length L may e.g. be about 5-40 meters such as 10-20 meters, e.g. about 15 meters long. But again, the length L may in embodiments of the invention be adjusted by moving the end stops 10, or vary between different groups 3_1-3_N

Fig. 3c illustrates an embodiment of the invention wherein multiple mould groups 3 1-3 N are arranged in rows Rl-Rn and in the end of each other.

The distribution unit may thus, e.g. on rails 30, wheels or the like be configured for moving in the first movement direction FMD which is in the longitudinal direction LD of the moulds, and the second direction SMD transverse to the longitudinal direction LD as explained above and/or below, thereby supplying the composite material to the mould groups 3 1-3 N.

In an embodiment of the invention, a user may thuds by a user interface select a row Rl-Rn whereby the distribution unit moves to the correct row, and the user may moreover select a pile group type (e.g. defined by width W2 of the pile moulds in the pile mould group. The user may also arrange the distribution unit 4 in the correct position in along the longitudinal direction LD, and then initiate the casting session. The distribution unit is thereby controlled by a control arrangement to move in the longitudinal direction LD and supply composite material such as concrete to the mould group by means of the outlet units 8_l-8_n selected based on the mould type and/or location.

The distribution unit 4 is thus preferably moved along the group of moulds which are arranged in parallel 3_la-3_ln in the direction LD during a casting session.

Alternatively, the mould groups may be moved in their longitudinal direction during casting and/or a combination thereof.

The side walls 19 between the mould groups 3 1-3 N separates the mould groups arranged in the mould group rows Rl-Rn next to each other, and some of the end walls/end stops 10 separates mould groups 3 1-3 N arranged in the same mould group row Rl-Rn. Fig. 4 schematically illustrates embodiments of a control arrangement 2 comprising a user interface UI and a control unit CU. The user interface UI may comprise a touch screen with a graphical user interface for accessing the different control functions of the casting apparatus 1, e.g. a SCADA based (Supervisory Control And Data) system or any other suitable kind of user interface UI.

The user may thus e.g. define relevant positions for the distribution unit 4, select casting templates related to different mould groups and/or the like by means of the user interface UI.

The control unit CU may thus receive control instructions from the user interface and moreover in embodiments of the invention provide control information to the user interface as indicated by the arrow between the user interface UI and the control unit CU.

The control arrangement 2 may in embodiments of the invention be provided by any suitable control means, including a computer processor. For example, it may be PLC (Programmable logical controller) based, and include a plurality of digital and/or analog input/output units and/or it may comprise a communication bus for transmitting and receiving control signals. It also comprises data storage comprising a computer program which, when executed by the control arrangement 2, provides one or more of the embodiments/aspects disclosed in this document. The control unit CU thus transmit control signals to individual outlet units 8a-8n by communication means 15 so as to control the outlet units and thereby the supply of composite material 6. The communication means 15 may in embodiments of the invention comprise electrical signals and/or pneumatics in. For example, an electrical signal may be transmitted from the control unit CU to an electrical relay or another type of electrical control means or the like, which opens and closes for a fluid (e.g. pneumatic valve) based on the electrical signal. Hence, the apparatus 1 may comprise relays and/or the like corresponding to the number of outlet units which may e.g. comprise pneumatic valves.

The control arrangement 2 may moreover in embodiments of the invention be configured to transmit control signals to drive means 16, 17 such as electrical motors or the like, in order to provide movement of the distribution unit in the longitudinal direction of the moulds e.g. during casting and/or between casting sessions and/or movement of the distribution unit 4 in a direction SMD transverse to the longitudinal direction between casting sessions.

Also the control arrangement 2 may in embodiments of the invention be configured to transmit control signals to drive means 66 (see fig 6) such as electrical motors or the like, in order to provide movement of a buffer in a second, transverse direction SMD between a delivery location and a receiving location.

Fig. 5 illustrates schematically an embodiment of the invention wherein the casting apparatus 1 comprises a level sensor arrangement 40a-4n, preferably comprising a plurality of level sensors 40a-40n. The level sensor arrangement 40a-40n detects the level of composite material 6 supplied to the moulds by the outlet units 8a-8n. The outlet unit reference numbers and the reference numbers to the moulds are not illustrated in fig. 5 in order to provide a more simple drawing. The level sensor arrangement detects the composite material surface level in one or more moulds (in the present example each pile mould). The control unit CU thus receives input signals from the sensors, and based thereon, the supply of composite material 6 by the outlet units 8a-8n is thus controlled by the control unit CU based on the sensor arrangement. The level sensor arrangement preferably comprises a plurality of level sensors 40a- 4n distributed in a direction transverse to the first movement direction FMD which first movement direction is in the longitudinal direction LD of the moulds. The control of supply of composite material to each mould may thus in embodiments of the invention be provided provide individually for each mould based on input from one or more of the level sensors.

The level sensors may comprise an ultrasonic sensor, an optical sensor and/or the like suitable for detecting a surface level change of the composite material such as a concrete material in the moulds.

The level sensor arrangement may comprise any suitable number of sensors 40a-40n. E.g., in embodiments of the invention, the level sensor arrangement may comprise level sensors that are not used during some casting sessions as the number of moulds in a mould group 3 1-3 N is less than the number of level sensors. This may e.g. be relevant if the mould group comprises six moulds while the casting apparatus facilitates providing composite material to e.g. ten moulds in another mould group. The control arrangement 2 may in embodiments of the invention control the distribution unit 4 to provides at least two movements of the distribution unit in the longitudinal direction LD of a mould group, including a first movement where the moulds are initially supplied with composite material, and a second, subsequent movement where supplementing composite material is supplied to the same moulds based on feedback from said level sensor arrangement so as comply with a predefined level threshold. The number of outlet units for supplying composite material may e.g. be changed between the first and second movement, e.g. to provide a more controllable flow of composite material during the supplementing supply. This may e.g. be based on input signals from the level sensor arrangement 40a-40n. The level sensors may in embodiments of the invention be arranged movable on a rod or the like in order to allow position adjustment of the sensors when selecting different types of moulds such as moulds with different widths W2. This adjustment of the sensors may e.g. be provided in a direction (e.g. in the second movement direction SMD) transverse to the first movement direction FMD and preferably provided by movement means such as electric motors in order to arrange the level sensors in a suitable location.

In other embodiments of the invention, the apparatus may comprise a number of level sensors corresponding to the number of outlet units, e.g. corresponding to the number of outlet units arranged in an outlet unit row, see more details later on.

Fig. 6 schematically illustrates a casting apparatus 1 according to embodiments of the invention.

The casting apparatus comprises the distribution unit 4, which is supplied with composite material 6 from the first buffer container 13 containing composite material 6 to be supplied to the moulds by the outlet units 8 1-8 based on control signals from the control arrangement 2 (not illustrated in fig. 6).

The distribution unit 4 is connected to a support structure 50, in this case by the frame structure 14. The support structure 50 may as illustrated comprise one or more beams extending horizontally in a second direction transverse to the longitudinal direction LD of the moulds 3_la-3_Nn.

The distribution unit 4 is thus movably arranged at the support structure (50) to be displaced by drive means 17 such as an electric motor in the second direction so as to supply composite material to different groups of moulds during different casting sessions. This movement may as illustrated, in embodiments of the invention be facilitated by the distribution unit 4 hanging from the support structure 50 and being movable on one or more rails 51 by one or more wheels at wheel arrangements 52. The support structure 50 support on a floor or another support foundation 53 through one or more first and second vertical beams 54, 55.

The control unit is moreover movable in the first direction in the longitudinal direction LD of the moulds 3_la-3_Nn.

The first vertical beam(s) 54 in the present example support on a rail 57 on the floor, but in other embodiments, it may be one or more wheels supporting directly on the support foundation.

The second vertical beam(s) 55 is kept in a fixed position and comprises a rail 56 in the upper part of the second vertical beam(s) 55. Alternatively, this may be provided by a solution as the vertical beam 54 which is movable in the longitudinal direction of the moulds.

The rails 56, 57 are arranged to extend along the moulds 3 1 a - 3_Nn in the first direction (longitudinal direction LD of the moulds), and thus, drive means 16 such as an electrical motor may provide the movement in the first direction along the rails 56, 57, for example during a casting session.

In a further embodiment of the invention, the apparatus 1 comprises a first material buffer 13, preferably a buffer container for containing composite material as e.g. described previously. This buffer container 13 is arranged to move in the second movement direction SMD simultaneously with the distribution unit 4 and is arranged above the outlet units 8_l-8_n.

In an embodiment of the invention, the supply arrangement of the apparatus 1 may moreover comprise a second material buffer 11 configured to travel between a delivery location DLO and a receiving location RLO, preferably in the second direction SMD. The second material buffer 11 receives composite material 6 at the receiving location RLO, from a composite material loader 90 (not necessarily part of the apparatus) and delivers the composite material 6 received from the material loader 90 to the distribution unit at the delivery location DLO, so that the composite material 6 is available to the distribution unit 4.

The delivery location delivery location DLO is preferably determined by the position of the distribution unit 4, so that second material buffer 11 delivers the received composite material to the distribution unit 4 at the location of the distribution unit no matter if the distribution unit is arranged to different locations along the second direction SMD at different times.

The second material buffer 11 comprises a container for the composite material, and may be movably on one or more rails 60 by wheels 61. The second material buffer 11 comprises one or more outlets 64 at the bottom of the container and one or more slides/doors 63 to be controlled so as to provide the composite material of the buffer material to eventually be received at the first buffer 13

The apparatus 1 may moreover comprise a third buffer container 12 arranged between the first and second buffers 11, 13 (when the buffer 11 is arranged substantially above the distribution unit 4). The third buffer container 12 provides an intermediate storage of composite material in a space of the buffer container, and comprises one or more outlets 74 at the bottom, and one or more slides/doors 73 that are controllable by e.g. the control arrangement 2. The third buffer container 12 may as the first buffer container 13 be configured to be movable with the distribution unit 4 (and in embodiments of the invention be considered as part of the distribution unit), and e.g. be connected to the frame structure 14.

The apparatus 1 may in embodiments of the invention comprise one or more amount sensors 81, 82, 83, preferably weight sensors, but it may also be optical sensors or any other suitable sensor means. This/these one or more amount sensors 81, 82, 83 may be configured to detect the amount of composite material such as a concrete material in a "liquid", uncured state in one or more of the buffer containers 11, 12, 13. Based on a reference value stored in a data storage of the control arrangement 2, the control arrangement can determine when more composite material should be added to one or more of the buffer containers 11, 12 and/or 13 to provide an even flow of composite material 6 to the moulds 3_la-3_Nn during one or a plurality of casting sessions.

Fig. 7 illustrates a flowchart with embodiments of the operation of the apparatus 1 by means of the control arrangement 2 according to embodiments of the invention.

In test T71 (ICS?), the apparatus tests if a casting session should be initiated. This may e.g. be determined by a user by pressing one or more physical buttons or buttons visualized in a graphical user interface of a user interface of the apparatus 1 , it may be determined by one or more position sensors such as RFID tags or the like arranged at a given mould group and or the like.

For example, a user may select a mould group row Rl-Rn, see above, and e.g.

determine a mould group type such as e.g. a group of a predefined type pile moulds 3_la-3_ln. This may e.g. be provided by the user interface making it possible to select a mould width W2, see fig. 3a by the user interface UI.

Based on this selection, the apparatus selects a casting template among different casting templates, and thereby selects one or more outlet units 8_l-8_n for supplying composite material to each mould in the selected group of moulds 3 1-3 N, see Step S71 (Deter. Cast temp.). The casting template may e.g. also include information of the movement speed in the first movement direction FMD, i.e. in the longitudinal direction of the mile moulds, and/or position(s) and/or orientation(s) of one or more level sensors of a level sensor arrangement 40a-40n so that the control arrangement (or a user) can place the level sensor(s) in a position(s) and/or orientation(s) suitable for the given mould group. The distribution unit 4 is then moved to an initial position (S72 - Mov. Distr. Unit to start), this may be provided by a user by means of the user interface, and/or by the control arrangement 2 according to a program code, thereby that enabling one or more drive means 16, 17 such as electric motors and thus moving the distribution unit 4 to an initial position.

In test T71 (ESD?), the control arrangement 2 tests if one or more end indicators such as end stops 10, end indicators such as an RFID (Radio frequency

identification) tag and/or the like is detected, thereby indicating that a casting session can be initiated. This may e.g. be provided by RFID Sensor(s), optical sensor(s), by means of position detection by utilizing a stepper motor for the movement and having a mapping over the positions of the moulds and/or the like so as to determine the position of the distribution unit relative to a mould group. In step S73, the, the casting session is initiated by a user by means of the user interface and/or by the control arrangement 2.

The casting session comprises that the control arrangement 2 opens the selected outlet units 8_l-8_n, (Step S73, Op. sel. outl. units) e.g. based on the selected casting template, and providing a relative motion in the first, longitudinal direction LD of the moulds by drive means/arrangement 16 with a speed e.g. set by the casting template, or a more general, predefined speed used for different types of mould groups (step S74, distr. unit in FDR). During the casting session, the control arrangement tests T73 (ESD?), preferably substantially continuously, if another end indicators indicating that the other end of the moulds is reached, is detected. Alternatively, this may be provided by a suitable mapping of mould position(s) and a stepper motor solution. Until this is detected, the movement and the supply of composite material is continued (steps S73, S74) by the apparatus 1. In embodiments of the invention, the casting session is ended, step S710 when the test T73 is positive, i.e. the other end of the moulds in the respective mould group is reached. In embodiments of the casting session, the movement provided by step S74 may be adjusted by the control arrangement based on a level detection arrangement as described as e.g. described at other locations in this document, and the number of selected outlet units used may be varied accordingly. In other embodiments if the invention, a further movement of the distribution unit 4 in the first direction, i.e. in the direction of the longitudinal direction, is provided, preferably in the direction back to substantially the position where the casting session was initiated in step S73, e.g. as described in the following with reference to steps S75-S77 and tests T74-T75, It is understood that these steps and tests in

embodiments of the invention may be considered as optional, and thus not included in a casting session, whereas in other embodiments of the invention, they may be considered a part of the casting session.

In step S75, when the end indicator is detected, the movement direction is reversed, and the distribution unit is thus again moved in a first movement direction in the longitudinal direction of the mould group. During this second, "reverse" movement in the first direction, a level detection arrangement, e.g. as described above in relation to fig. 5, detects the height of the surface level of the composite material in more or more of the moulds. Based on input from the level detection arrangement, one or more or all of the outlet unit(s) of the selected outlet units for the casting session are opened or closed to provide further, supplementing composite material to the moulds of the mould group, until an end indicator is detected again, see test T75 (ESD). Thus, during the movement, the control arrangement receives input from the level sensor arrangement, and based thereon, the control arrangement tests (Test T74, L OK?) if the level is in accordance with a desired reference value. If the level is OK, the selected outlet units are closed (step S76, cl. Sel. outl. units) if not one or more of the selected outlet units are opened (step S77, op. Sel. outl. units) to provide supplementing composite material.

In embodiments of the invention, there may be a brief time break (not illustrated) before the movement in step S75 is initiated, to allow the composite material supplied during the movement initiated in step S74 to distribute sufficiently in the moulds of the mould group, e.g. around a reinforcement structure such as a metal wire/rod reinforcement structure arranged in the moulds before the casting session was initiated. During the time break, the selected outlet units are preferably closed, and one or more of the selected outlet units may thus be reopened when the movement initiated in step S75 is started.

Fig. 8 illustrates a flowchart with embodiments of the operation of the apparatus 1 in relation to assuring supply of composite material by buffer compartments 11, 12 and/or 13 as described in relation to e.g. fig. 6. by means of the control arrangement 2 according to embodiments of the invention.

As previously described, the apparatus may comprise amount sensors for

determining the amount of material on a material buffer. When the

detected/determined amount gets below a predetermined threshold in a buffer, 11, 12 and/or 13, the control arrangement 2 request further material.

As an example, the second material buffer 13 (fig. 6), may move (step S81) by drive means 66 such as an electric motor to the receiving location RLO to receive material from a material loader 90, and travel back to the delivery location DLO, e.g. above the distribution unit 4, and load the material into the suitable buffer 12 or 13 when an amount determinator (e.g. a computer implemented calculation utilizing a threshold and one or more sensor inputs) determine(s) that the amount A of composite material in the buffer(s) 12 or 13 is below a desired threshold At, test T81, e.g. an amount sensor 82 or 83 such as a weight sensor may provide input data for parameter A, see test 81. For example, if the weight of the composite material 6 in the buffer 13 is determined to be less than a weight threshold Tr, (preferably not completely empty to assure that an ongoing casting session can continue), the control arrangement may e.g. assure that material 6 in an intermediate, third buffer 12 is provided to buffer compartment 3, e.g. by opening gates 73 or the like. It may also initiate that the buffer 11 collects further material to be delivered to the buffer 12 by opening gate(s) or the like 63 above the location of the distribution unit 4 when at the delivery location DLR.

Fig. 9a illustrates embodiments of the invention wherein the control arrangement 2 comprises a data storage DS having casting template data C-TEl-CTEn and program code stored.

The template data comprises a plurality of different casting templates C-TEl-CTEn which relates to different types of moulds and/or mould groups. The casting templates preferably at least comprise sub-group information SGIl-SGIn.

The first sub-group information SGI1 is related to a first mould group type, e.g. a type comprising a plurality of moulds arranged next to each other and each having a width of W2, e.g. about (purely an example) 27cm. When a user or the control arrangement 2 selects the casting template C-TE1, e.g. by a user selecting a mould group type by a user interface, the control arrangement 2 selects the relevant outlet units 8_l-8_n to be used during a casting session for that mould group type.

This is explained in more details in relation to casting template C-TE2, where the second sub-group information SGI2 is schematically illustrated in fig. 9b.

As can be seen fom fig. 9b, the second sub-group information SGI2 comprises a plurality of subgroup information SGl-SGn. Each sub-group SGl-SGn is assigned one or more outlet units 8_l-8_n. for example, outlet units 8 1 and 8 2 are both assigned sub-group 1 (SGI), the outlet units 8 5 and 8 6 are assigned subgroup 2

(SG2) and vide versa. The example of fig 1 corresponds substantially to the selection illustrated in fig. 1 where eight subgroups are provided for supplying composite material to a mould group comprising eight moulds.

The number of subgroups may thus in embodiments of the invention vary dependent on the number of moulds in a subgroup.

In preferred embodiments of the invention, the number of outlet sub-groups SG1- SGn correspond to the number of oblong moulds in the mould group 3 1-3 N to receive composite material 6 simultaneously, and preferably, the total number of outlet units assigned to the outlet sub-groups SGl-SGn is higher the number of moulds to be supplied with the composite material during the casting session.

Returning to fig. 9a, it is understood that each template may comprise other information that is pre-set and thus used when selecting the respective template C-TE1 - C-Ten. For example, the templates C-TEl-C-TEn may comprise:

• preset movement speed information defining the movement speed of the distribution unit 4 during a casting session,

• Information of if a reduced number of outlet units should be used during a rearward movement of the distribution unit as described in fig. 7 for supplementing supply of composite material,

• position and/or orientation of that one or more level sensors of a level sensor arrangement should be arranged in in order to determine surface level in the moulds of a mould group,

• Etc.

The data storage DS may moreover comprise program code to be processed by the control unit CU of the control arrangement 2, e.g. to provide one or more of the functionalities described above such as in relation to fig. 7 and/or 8. For this, the control unit may receive data input DI from sensors, and provide control signals to drive means, outlet units, gates and/or the like by data output DO. The control arrangement may thus select and execute different templates C-TEl-C-TEn for different groups of mould types dependent on input from a user by a user interface as e.g. previously described.

Fig. 10 illustrates an embodiment of the invention, wherein the distribution unit 4 comprises a plurality of outlet unit rows OLR such as at least two, preferably substantially parallel, outlet unit rows (OLRl -OLRn) each comprising a plurality of outlet units 8_l-8_n. Each outlet unit row OLRl -OLRn extends in a direction transverse to said first movement direction of the distribution unit 4. There may however be three, four, five or six or even more outlet unit rows in further embodiments of the invention. The rows OLRl, OLRn are in this example displaced with a distance between the rows in the longitudinal direction of the moulds, but in other embodiments, the rows may substantially abut.

Hence, one, two, three or more outlet units of each outlet unit row OLRl, OLRn may be utilized for supplying the composite material 6 to each mould in a mould group. For example in the event of the mould group 3 1 as illustrated in fig. 1, the outlet units indicated with a cross in fig. 10 may be used.

In embodiments of the invention where a supplementing supply of composite material as described e.g. in relation to fig. 7 is provided, both rows of selected outlet units may be utilized during the first movement to supply material to the mould, and at least some of the outlet units, e.g. one outlet unit row may be deselected during the movement to supply further, supplementing composite material to the moulds of the mould group.

Fig. 11 illustrates an embodiment of a control device 100 for controlling the opening and closing of the outlet units 8_l-8_n seen from the side.

The control device 100 comprises a linear actuator having a housing 101 and a piston 102 which is displaceable inside the housing. The piston is rotatable connected to an outlet blocking device 103 through a first hinge connection 104. By displacing the piston 102 as illustrated, the outlet unit 8_n is either opened or closed.

The blocking device 103 preferably comprises a sealing 105 which assures a close seal when the blocking device 103 blocks the outlet 110 to close the outlet unit 8_n. The sealing 105 may be exchanged over time when worn down.

Hence, when closing an outlet unit, the control arrangement transmit a closing signal, and the piston 102 is thus moved outwards to arrange the blocking device 103 in a position where the composite material cannot leave the outlet 110 and into a mould (see example with dotted lines in fig. 10). When opening the outlet unit 8_n, the control arrangement transmits another signal, and the piston 102 thus moves inwards into the cylinder's housing 101, preferably by pneumatics, thus opening the outlet 110 and allowing the composite material such as concrete, into the mould.

The distribution unit thus preferably comprises control devices corresponding to the number of outlet units 8_l-8_n of the distribution unit.

The control device 100 may in other embodiments of the invention be substituted with other types of control devices, e.g. a control device actuated by a motor such as an electric motor and/or any other suitable device.

Fig. 12 illustrates schematically an embodiment of the casting apparatus 12 according to embodiments of the invention, seen from above. The mould groups such as groups of pile moulds for casting foundation piles may e.g. be arranged as illustrated in fig. 3c in different rows Rl-Rn.

The distribution unit 4 is arranged on parallel rails 51 extending in the second movement direction SMD. The rails 51 are arranged above the ground as illustrated in relation to figure 6, and the distribution unit 4 of the apparatus 1 is arranged between the rails 51 and supporting on wheel arrangements 52 on the rails to allow a movement by drive means 17, such as one or more electric motor, in the second movement direction SMD while supporting on rails 51. This allows that the distribution unit can 4 supply composite material to different rows Rl-Rn of mould groups 3_1-3_N as described above.

The apparatus 1 is moreover configured to support on parallel rails 57 extending in the longitudinal direction LD of the moulds. Thereby, the distribution unit 4 can be moved by drive means 16 such as one or more electric motors in the first movement direction FMD during a casting session and/or when moving the distribution unit 4 between different mould groups in a row Rl-Rn.

It is noted that the buffer 11 as illustrated in fig. 6 is not illustrated in fig 12 to provide simplicity of the figure. Moreover, such a distribution unit 11 and/or the "intermediate" buffer 12 as illustrated and described in relation to fig. 6 may in embodiments of the invention be omitted, and supply of composite material 6 may thus in embodiments of the invention instead moreover be supplied to the

distribution unit 4, e.g. into a buffer 13 by means of a pipe system (not illustrated).

In general, it is to be understood that the present invention is not limited to the particular examples described above but may be adapted in a multitude of varieties within the scope of the invention as specified in e.g. the claims. Accordingly, for example, one or more of the described and/or illustrated embodiments may be combined to provide further embodiments of the invention.

Claims

1. Method of producing oblong support structures such as foundation piles by means of a casting apparatus (1), which casting apparatus comprises:

a supply arrangement (11 , 12, 13) for supplying composite material (6) to be distributed by the casting apparatus (1),

a distribution unit (4) for distributing composite material (6) to groups (3 1- 3_N) of oblong moulds (3_la-3_Nn), which distribution unit (4) comprises a plurality of individually controllable outlet units (8_l-8_n) for distributing composite material (6) into said oblong moulds (3_la-3_Nn), and

a control arrangement (2) for controlling the supply of composite material (6) to said groups of oblong moulds, wherein said outlet units (8_l-8_n) are controllable by said control arrangement (2),

wherein the number of individually controllable outlet units (8_l-8_n) is larger than the number of moulds (3_la-3_Nn) in a group (3 1-3 N) of moulds that are simultaneously supplied with composite material by said casting apparatus (1) during a casting session, said method comprising: selecting a plurality of said outlet units (8_l-8_n) for supplying composite material (6) to moulds in a group (3 1-3 N) of moulds during a casting session, providing a relative movement between said distribution unit (4) and a selected group of moulds (3 1-3 N) in a first movement direction (FMD) during supply of composite material (6), which first movement direction (FMD) extends the longitudinal direction (LD) of the moulds to be supplied with composite material (6), and supplying composite material (6) to said group (3 1-3 N) of moulds by means of said selected outlet units (8_l-8_n) during said relative movement in said first movement direction (FMD).

2. Method according to claim 1, wherein said plurality of outlet units (8 1 - 8_n) are distributed at said distribution unit (4) in a direction transverse to said first movement direction (FMD).

3. Method according to claim 1 or 2, wherein said composite material (6) is supplied substantially continuously during said relative movement to the respective moulds (3_la-3_Nn) from a first end of the moulds to the opposite end of said moulds during said casting session by means of the selected outlet units and drive means (16) controlled by said control arrangement (2).

4. Method according to any of the preceding claims, wherein a plurality of outlet units (8_l-8_n) are selected for supplying composite material to the same mould (8_ln-8_Nn) during a casting session.

5. Method according to any of the preceding claims, wherein said selection of outlet units (8_l-8_n) comprises assigning said plurality of outlet units (8_l-8_n) to different outlet sub-groups (SGl-SGn), wherein the outlet sub-groups (SGl-SGn) simultaneously supply composite material to different moulds in a mould group (3_1-3_N), wherein the number of sub-groups (SGl-SGn) correspond to the number of oblong moulds (3_la-3_Nn) in the mould group (3 1-3 N) to receive composite material (6) simultaneously during said casting session, and wherein the total number of outlet units (8_l-8_n) assigned to said outlet sub-groups (SGl-SGn) preferably may be higher than the number of moulds to be supplied with said composite material (6) during the casting session.

6. Method according to any of the preceding claims, wherein said casting apparatus (1) comprises a level sensor arrangement (40a-40n), which level sensor arrangement detects the level of composite material (6) supplied to said moulds by the outlet units, e.g. by detecting the composite material surface in one or more moulds, wherein the supply of composite material (6) by said selected outlet units is controlled by said control arrangement (2) based on data input (DI) from said level sensor arrangement.

7. Method according to claim 6, wherein said level sensor arrangement (40a-40n) comprises a plurality of level sensors distributed in a direction transverse to said first movement direction (FMD), and wherein the control of supply of composite material to each mould in a group (3 1- 3_N) is preferably provided individually for each mould during a casting session based on input from one or more of said level sensors detecting the composite material level in the respective mould.

8. Method according to any of the preceding claims, wherein said distribution unit (4) provides at least two movements in the first movement direction (FMD) during a casting session, including a first movement where the moulds are initially supplied with composite material, and a second, subsequent movement where further composite material is supplied to the same moulds, preferably based on data input from said level sensor arrangement so as comply with a predefined level threshold (At).

9. Method according to any of the preceding claims, wherein said distribution unit (4) is displaced by drive means (17) in a second movement direction (SMD) substantially transverse to said first movement direction (FMD) so as to supply composite material to one or more further groups (3_l-3_n) of moulds during further casting sessions.

10. Method according to any of the preceding claims, wherein said selection of a plurality of outlet units (8_l-8_n) comprises that a subset of said plurality of outlet units (8_l-8_n) is selected for supplying composite material to a group (3 1-3 N) of moulds, wherein said selection preferably is based on a mould type selected among a set of different predefined mould types, preferably by means a user interface (UI).

11. Method according to any of the preceding claims, wherein said control arrangement (2) adjusts one or more operational parameters to a predefined setting based on the identified mould type, wherein said operational parameters comprises one or more of the following

Movement speed in said first movement direction

the position and/or orientation of a plurality of level sensors of a level sensor arrangement of said apparatus.

12. Method according to any of the preceding claims, wherein said apparatus (1) is configured for providing composite material to a plurality of groups of moulds by means of said control arrangement (2) by moving said distribution unit (4) to different positions,

wherein each group (3_1-3_N) of moulds (3_la-3_lNn) comprises a plurality of moulds arranged in parallel, and

wherein said groups of moulds comprises moulds of different sizes, and

wherein the width (Wl l-Wl n) of the different groups of moulds to be supplied with composite material preferably is substantially identical.

13. Method according to any of the preceding claims, wherein said plurality of outlet units (8_l-8_n) are arranged in a substantially fixed position relative to each other at said distribution unit.

14. Method according to any of the preceding claims, wherein said plurality of outlet units (8_l-8_n) of said distribution unit (4) comprises at least two outlet unit rows (OLRl-OLRn) each comprising a plurality of outlet units (8_l-8_n), where each outlet unit row extend in a direction transverse to said first movement direction of said distribution unit (4).

15. Method according to any of the preceding claims, wherein said casting apparatus comprises a plurality of casting templates (C-TE 1 - C-TE n) wherein each casting template (C-TE 1 - C-TE n) comprises information (SGl-SGn) of which outlet units (l_l-8_n), such as outlet unit sub-groups, that should be used for providing composite material to the respective moulds of a mould group (3 1- 3_N), and wherein different combinations of outlet units (l_l-8_n) are used for providing composite material (6) dependent on the selected casting template (C-TE 1 - C-TE n).

16. Method according to any of the preceding claims, wherein said supply arrangement (11, 12, 13) comprises a first material buffer (13) arranged so as to store and supply composite material (6) to said outlet units of the distribution unit (4).

17. Method according to claim 16, wherein said first material buffer (13) is arranged to move in a second movement direction (SMD) transverse to said first movement direction (FMD), preferably simultaneously with said distribution unit (4).

18. Method according to any of the preceding claims, wherein said supply arrangement comprises a buffer (11, 12, 13) such as a second material buffer (11), configured to travel between a delivery location (DLO) and a receiving location (RLO), wherein said material buffer (11, 12, 13) receives composite material (6) at said receiving location (RLO), preferably from a material loader (90), and delivers the received composite material (6) at the delivery location (DLO), wherein said delivery location (DLO) preferably is determined by the position of the distribution unit (4), and wherein the second material buffer delivers the received composite material to said distribution unit (4), preferably to said first material buffer (13), e.g. through an intermediate third buffer (12).

19. Method according to any of the preceding claims, wherein said moulds (3 1 a- 3_Nn) have a length from a first end wall (10) to a second end wall (10) of the moulds, such as foundation pile moulds, which length is between 5 and 25 meters such as e.g. between 13-17 meters, and wherein said length preferably substantially corresponds to the length that said distribution unit (4) travels between the end walls in said first movement direction (FMD) in order to supply said composite material (6) during a casting session.

20. Method according to any of the preceding claims, wherein the width (W2) of said moulds (3_la-3_ln) is between 100mm and 1000mm such as between 150mm and 700mm, e.g. between about 200mm and 400mm including both endpoints.

21. Method according to any of the preceding claims, wherein different combinations of outlet units (8_l-8_n) is selected dependent on the width (W2) of the moulds of the mould groups (3_1-3_N).

22. Method according to any of the preceding claims, wherein one or more, preferably all, of said groups (3_1-3_N) of oblong moulds (3_la-3_Nn) comprise at least four such as at least five, e.g. at least six such as at least seven moulds in a group, and/or wherein said moulds are located in a production facility comprising at least ten, for example as at least twenty, such as at least thirty groups of moulds such as foundation pile moulds.

23. A casting apparatus (1) for producing oblong support structures, such as foundation piles, which casting apparatus (1) comprises:

a distribution unit (4) for distributing composite material (6) to groups (3 1-

3_N) of oblong moulds (3_la-3_Nn), which distribution unit (4) comprises a plurality of individually controllable outlet units (8_l-8_n) for distributing composite material (6) into said oblong moulds (3_la-3_Nn), and

a control arrangement (2) configured for controlling the supply of composite material (6) to groups (3 1-3 N) of moulds, wherein said outlet units are individually controllable by means of said control arrangement (2), wherein said apparatus (1) comprises selection means (UI, 2) configured for selecting outlet units (8_l-8_n) of said distribution unit (4) for supplying composite material to moulds (3_la-3_ln) in a group of moulds (3 1-3 N) during a casting session, wherein said selection means (2, UI) are configured to select a subset of said plurality of individually controllable outlet units (8_l-8_n) for supplying composite material (6) to said group of moulds (3 1-3 N), which subset of individually controllable outlet units (8_l-8_n) comprises a plurality of said outlet units (8 1- 8_n), and wherein said apparatus (1) is configured for providing a relative movement between said distribution unit (4) and a selected group (3 1-3 N) of oblong moulds in a first movement direction (FMD) during supply of composite material to a selected group (3_1-3_N) of moulds by means of said selected subset of outlet units (8_1-8_N).

24. A casting apparatus (1) according to claim 23, wherein said selection of outlet units (8_l-8_n) comprises assigning said plurality of outlet units (8_l-8_n) of said subset to different outlet sub-groups (SGl-SGn), wherein the outlet sub-groups (SGl-SGn) are configured for simultaneously supplying composite material (6) to different moulds.

25. A casting apparatus (1) according to claim 23 or 24, wherein said plurality of outlet units (8 1 - 8_n) are distributed at said distribution unit (4) in a direction transverse to said first movement direction (FMD).

26. A casting apparatus (1) according to any of claims 23-25, wherein said apparatus (1) is configured so that composite material (6) is supplied substantially continuously to the respective moulds (3_la-3_Nn) in a group (3_1-3_N) during said relative movement in the first movement direction (FMD) from a first end of moulds to the opposite end of said moulds during a casting session.

27. A casting apparatus (1) according to any of claims 23-26, In preferred aspects of the casting apparatus, the apparatus (1) is configured so that a plurality of outlet units of said subset are selected for supplying composite material (6) to the same mould, e.g. by being member of the same sub-group.

28. A casting apparatus (1) according to any of claims 23-27, wherein said casting apparatus (1) comprises a level sensor arrangement (40a-40n), which level sensor arrangement is configured to detect the level of composite material supplied to said moulds (3_la-3_ln) by the outlet units, e.g. by detecting the composite material surface in one or more moulds, and wherein the supply of composite material by said outlet units is configured to be controlled by said control arrangement (2) based on data input (DI) from said level sensor arrangement.

29. A casting apparatus (1) according to any of claims 23-28, wherein said distribution unit (4) is configured to be displaced by drive means (17) in a second movement direction (SMD) substantially transverse to said first movement direction (FMD) so as to supply composite material to one or more further groups (3 1-3 N) of moulds.

30. A casting apparatus (1) according to any of claims 23-39, wherein said selecting of one or more of said outlet units (8_l-8_n) comprises identifying a mould type among a set of different predefined mould types, preferably by a user interface (UI), and wherein said control arrangement (2) is configured to provide said selection if a subgroup of outlet units (8a-8n) based on the identified mould type.

31. A casting apparatus (1) according to any of claims 23-30, wherein said plurality of outlet units (8_l-8_n) are arranged in a substantially fixed position relative to each other at said distribution unit (4).

32. A casting apparatus (1) according to any of claims 23-32, wherein said plurality of outlet units (8_l-8_n) of said distribution unit (4) comprises at least two outlet unit rows (OLRl-OLRn) each comprising a plurality of outlet units, where each outlet unit row extend in a direction transverse to said first movement direction of said distribution unit (4).

33. A casting apparatus (1) according to any of claims 23-32, wherein said apparatus is configured so that said selection of said subset of outlet units is configured to be provided based on a plurality of casting templates (C-TE 1 - C-TE n) stored in a data storage (DS) of said control arrangement (2).

34. A casting apparatus (1) according to claim 33, wherein each of said casting templates (C-TE 1 - C-TE n) comprises information (SGl-SGn) of which outlet units (l_l-8_n), such as outlet unit sub-groups, that should be used for providing composite material to the respective moulds of a mould group (3 1-3 N), and wherein said apparatus (1) is configured so that different combinations of outlet units (l_l-8_n) are used during a casting session for providing composite material (6) dependent on the selected casting template (C-TE 1 - C-TE n).

35. A casting apparatus (1) according to any of claims 23-34, wherein said supply arrangement at least comprises a first material buffer (13) arranged to supply composite material (6) to said outlet units (8_la-8_ln) of the distribution unit (4).

36. A casting apparatus (1) according to any of claims 23-35, wherein said apparatus comprises one or more support structures (50) such as one or more beams extending horizontally, and wherein the distribution unit (4) is movably arranged at said one or more structures, e.g. by means of rails, so as to provide a movement of said distribution unit (4) in a second movement direction (SMD) transverse to said first movement direction (FMD).

37. A casting apparatus (1) according to any of claims 23-36, which casting apparatus (1) is configured to operate in according to the method of one or more of claims 1-22.

38. A system comprising a casting apparatus (1) and a plurality oblong moulds for producing oblong support structures, such as foundation piles, wherein said casting apparatus (1) is a casting apparatus according to any of claims 23-37, and wherein said plurality oblong moulds of said system comprises groups (3 1-3 N) of oblong moulds (3_la-3_Nn), each group comprising at least four such as at least five, e.g. at least six such as at least seven moulds in a group, and/or wherein said moulds are located in a production facility comprising at least ten, for example as at least twenty, such as at least thirty groups of moulds such as foundation pile moulds.

(Fig- 1)