EP4036342A1 - Reinforcement support device, reinforcing assembly, device and method for manufacturing a reinforcing assembly and method for manufacturing a concrete member - Google Patents

Abstract

Reinforcement support device for receiving, holding and deflecting a yarn (32) to form a textile reinforcement (29), the reinforcement support device (1) having yarn holding devices (40, 46, 52, 56, 58) which have a slot for insertion and/or for Have welding of the yarn (32). The yarn holding devices (40, 46, 52, 56, 58) are arranged on an at least two-dimensional receiving structure (34) made of a flat material on its surface, with the dimension between the surface of the receiving structure (34) and the position of the inserted in the slot Yarn (32) determines the distance between the receiving structure (34) and the textile reinforcement (29). Device and method for producing a reinforcement arrangement (30), comprising at least one robot arm (14) and/or a portal device (16), which have at least one working head (20, 26) that can be moved at least in two dimensions. The robot arm (14) and/or the portal device (16) comprise a device for positioning the yarn holding devices (40, 46, 52, 56, 58) and a device for yarn deposit. Process for the production of a single or multi-curved concrete component.

Description

The invention relates to a reinforcement support device for receiving, holding and deflecting a yarn to form a textile reinforcement, the reinforcement support device having yarn holding devices which have at least one slot that is accessible in at least one direction from a first side, an upper side, or at least one slot that is accessible perpendicularly to the upper side Have slot for inserting and / or for welding the yarn. The invention also relates to a reinforcement arrangement, comprising at least one textile reinforcement, formed at least from one yarn, and furthermore to a device for producing a reinforcement arrangement, comprising at least one robot arm and/or a portal device, which has at least one working head that can be moved at least in two dimensions, and a method for production a reinforcement arrangement. A further aspect of the invention relates to a method for producing a single or multiple curved concrete component in a formwork.

For the production of reinforced concrete components, formwork is generally used, into which reinforcement, for example made of steel, is inserted and secured in its position. This formwork is then filled with concrete, resulting in a reinforced concrete component. During concreting, both the reinforcement and any fixtures to be embedded in the concrete must be secured in place. The reinforcement often consists of rods or grids, which have little flexibility in shape or high rigidity. This simplifies their manufacture and position securing during the concreting process. However, the high rigidity of the reinforcement means that it can only be placed linearly and therefore has to follow straight lines. Furthermore, the reinforcement layout is often planned and executed in terms of the simplest possible manual installation. This also means that the reinforcement is not optimally used in terms of structural mechanics in terms of its shape and position.

Steel reinforcements have been used for over 130 years. The technologies for securing the position during the concreting process are correspondingly well developed. However, conventionally only uniaxial reinforcements or reinforcements with large radii are used. If smaller radii are to be created, they are usually created externally by bending the steel reinforcement. The resulting ones Stirrups are attached to the rest of the reinforcement - usually with the help of a wire.

The main disadvantages of steel reinforcement are its rigidity and susceptibility to corrosion. Furthermore, the processes for creating and positioning stirrups or curved reinforcements are only possible with a great deal of effort. According to the state of the art, a high proportion of manual work is common here, and automation is only possible to a limited extent.

Textile reinforcements made of textile yarns, such as carbon yarns, glass filament yarns or similar, allow flexible reinforcement, provided the surrounding matrix is not too stiff. As a rule, biaxial fabrics made of carbon or glass are used. These scrims are held in place using spacers. Furthermore, rods made of carbon or glass are used, which are held in the intended position with spacers, wire or other holding devices, analogous to reinforced concrete.

Compared to steel reinforcement, reinforcement made of carbon or glass fibers has the advantage of being basically malleable. The stiffness of the textile is only increased by adding a coating (which is necessary, among other things, for the bonding behavior between yarn and concrete and at least between the individual filaments). After coating, the fibers can no longer be easily shaped. The reinforcement routing - and thus the position of the reinforcement fibers in the concrete component - is therefore subject to and limited by the existing technologies for placement and positioning. For the component, this means that the reinforcement cannot be optimally inserted into the component, but is always subject to compromises and tends to follow straight lines (uniaxial placement). This generally results in yarn misalignment and consequent inefficient utilization of the fiber substance. This in turn leads to oversizing and thus to a waste of resources (increase in CO ₂ emissions and price increases), can lead to structural damage and reduced service life and also make recycling more difficult.

Another way to reduce the use of resources and to increase the aesthetics of buildings is the use of single or double curved components. The reinforcement layout of such curved components is a special one A challenge. The reinforcement must be able to follow the shape of the component and at the same time be secured against floating or sinking during the concreting process. This positioning and securing of the position in the third dimension is a technical challenge that conventional methods cannot cope with.

Efforts are also known from the prior art which allow free but still uniaxial yarn placement. These are, for example, in the publication DE 10 2016 100 455 A1 described. Here the technical problem is solved by deflection rollers, which are placed on the edge of a formwork table. A soft roving is used to enable free reinforcement. This is pulled through an impregnation bath and deposited. The hardening of the impregnation (often by inserting it into an oven) creates a stiff reinforcement, which is then removed from the deflection rollers and placed on the formwork table.

That through the print DE 10 2016 100 455 A1 The method described attempts to circumvent this problem of the stiff coating by only hardening the coating after the deposition process. This leads to a great deal of effort when it comes to machine maintenance, in particular the maintenance-intensive coating unit. Furthermore, the necessary process steps (positioning of the deflection rollers, coating, yarn placement, separation of the rollers and the yarn, curing process in an external oven, positioning of the reinforcement on the formwork) are very time-consuming.

In addition, a free reinforcement routing through the in the publication DE 10 2016 100 455 A1 The method described is still only possible to a limited extent, since a change in direction is only possible through the deflection rollers and thus in the outer area of the component. The yarn is also guided uniaxially, ie in one direction across the entire width, from deflection roller to deflection roller. A change of direction between two deflection rollers or elements is not possible due to the process. The elements are only intended for the outer edge and do not remain in the concrete part. The production of reinforcement for curved components is therefore only possible to a very limited extent.

From the pamphlets CN 202658807 U , DE 10 2015 104 830 A1 , JP 2006219895 A and JP 2000064508 A are different yarn holding devices for a textile Reinforcement is known, which, however, does not form an easy-to-use reinforcement support device and is also not suitable for this. The pamphlet EP 3 418 465 A1 describes a method for producing a three-dimensional building material component 20, see there 11 , which is also suitable for forming a concave and/or convex curved surface. A plurality of spacer bodies 32 are arranged in a formwork 30 . A textile reinforcement 21 is supported on the spacer bodies 32 so that the textile reinforcement 21 has a defined position within a formwork interior 30a of the formwork 30 . The spacer bodies 32 have to be arranged in a complex manner and connected individually with a connecting element 34, cf. figures 13 and 14 and the associated description in Appendices [0040] to [0044]. In addition, the spacer bodies 32 can only hold the yarn that has been laid on securely if it is under sufficiently high tension.

The development and production of machines for variable reinforcement routing is associated with high costs and time. A purchase would therefore only be profitable for a company if there was sufficient demand. Since a delivery of heavy concrete components over more than 100 km is usually not economical, the demand for such machines is limited. A central production of the shape-optimized reinforcement in a single plant and subsequent delivery and concreting in decentralized precast plants would make it possible to spread the development and procurement costs over several precast plants. The form of reinforcement must be held in a correspondingly stable position so that the position of the reinforcement can still be guaranteed even after transport. This is not possible with the conventional methods for laying down the reinforcement, since these are based on central production and positioning of the reinforcement in the formwork immediately before the concreting process. Conventional methods therefore do not allow the transport of an existing reinforcement.

In addition to the reinforcement, other built-in parts must also be secured in their position. This applies, for example, to transport anchors, connecting elements, cables or electrical connections. All in all, the technical challenge relates to securing the position of built-in parts and reinforcement - especially with a variable axial reinforcement layout and curved components - both during transport and during the concreting process.

It is therefore the object of the present invention to propose a simple reinforcement support device for the free positioning of a yarn of a textile reinforcement and thus a free reinforcement guidance, a variable axial placement, and a solution for the positioning and position securing of such a reinforcement arrangement, including any built-in parts, during the offer concreting process. It is also an object of the present invention to propose a reinforcement arrangement, the production of the reinforcement arrangement using a suitable device and a suitable method, and the production of reinforced components with single or multiple curvatures.

The object is achieved by a reinforcement support device for receiving, holding and deflecting a yarn to form a textile reinforcement. The reinforcement support device has yarn holding devices which have at least one slot accessible from a first side, an upper side, in at least one direction or at least one slot accessible perpendicularly to the upper side for inserting and/or welding the yarn. According to the invention, the reinforcement support device comprises yarn holding devices, which are arranged with a second side, an underside, on an at least two-dimensional receiving structure made of a flat material on the surface thereof. The dimension between the surface of the receiving structure and the position of the yarn inserted in the slot determines the distance between the receiving structure and the textile reinforcement.

In addition to the head part, the preferred yarn holding devices also comprise a foot part, designed for connection to a receiving structure formed at least two-dimensionally in the first plane at any assembly location on its surface in the first plane. At each node, formed by a yarn holding device, the yarn can change its direction. In this way, a variable axial yarn placement is made possible.

Yarn holding devices which have an increased radius or webs in the lower area facing the receiving structure have proven to be particularly advantageous. In this way, the yarn holding device can be welded to the receiving structure by means of ultrasonic welding by means of a cylindrical, hollow sonotrode which presses onto the webs. Different to for example the rivet connection, this allows the connection to be made solely from the top of the receiving structure.

The yarn holding devices are also used to create a connection between the receiving structure and any built-in parts (e.g. empty tubes, capillary tubes, cables, anchoring elements). For this purpose, special brackets such. B. a cable holder can be used advantageously.

The built-in parts are attached, for example, by means of a yarn holding device. The yarn holding devices with a slot are suitable for this purpose in order to connect reinforcement yarns, capillary tubes or cables to the receiving structure. Other versions are suitable for connecting round anchoring elements. In a first step, the yarn holding device is welded onto the receiving structure using a flat sonotrode, and in a second step the anchoring element is positively connected to the yarn holding device. Furthermore, the yarn holding device can have a hole in the middle through which a cable can be passed. As a result, the cable can be attached to the yarn and guided to the outside of a concrete component according to the invention. This is used when the yarn is to be used for heating or for the transmission of electrical signals or energy.

Furthermore, the yarn holding device can be designed in such a way that a cylinder with a tapering slot on the side, also referred to as a groove, results. A yarn can be guided around this type of yarn holding device, hereinafter referred to as a deflection yarn holding device, and deflected if necessary. This is also glued, welded, screwed or otherwise connected to the receiving structure. In this way, the yarn can be deflected at any point and secured in its position. This enables variable axial yarn placement.

The foot part of the yarn holding devices is, where explained in more detail above, designed to be welded to the receiving structure, in particular by means of ultrasound (which is preferably done from the top), riveted (which is done from the bottom), clamped, glued, screwed and/or magnetically to be connected, either temporarily or permanently.

The previously mentioned sonotrodes are used for ultrasonic welding to create the connections. They are set into resonant vibrations by introducing high-frequency mechanical vibrations and thus temporarily or permanently weld the yarn holding device to the receiving structure.

In addition, the yarn can be connected to the yarn holding device. If a flat sonotrode is used, it is advantageous if the yarn holding device has at least one slot into which the yarn is inserted. A flat ultrasonic sonotrode is then pressed onto the yarn holding device from above. As a result, the plastic is deformed in such a way that the yarn connects to the yarn holding device, but at least it is prevented from leaving the then closed slot undesirably. During ultrasonic welding, the temperature is only transferred locally to the yarn holding device, which means that the yarn remains undamaged.

Furthermore, according to an alternative embodiment, the connection between the yarn holding device and the receiving structure can be realized by riveting. For this purpose, the yarn holding device has a foot part, which ends in a rivet foot, also referred to as a rivet extension, a preferably cylindrical extension at the base, which is guided at the installation site through an opening in the receiving structure from a first side and then, in particular by means of ultrasonic welding, is riveted from a second side. A sonotrode is therefore also preferably used for riveting.

Furthermore, a plastic part can be used as a yarn holding device, which implements a mechanical click connection, hereinafter referred to as a click yarn holding device. This element is preferably manufactured using the injection molding process. It is glued, welded or riveted to the receiving structure on the underside. The twine is connected to the twine holding device by a click connection. This mechanical connection is usually faster than welding, but has the disadvantage that the yarn remains axially displaceable.

As an alternative to welding or riveting, the yarn holding device can also be bonded, screwed or magnetically connected to the Recording structure and connected to the yarn. Mixed forms can also occur.

The height of the yarn holding device, but in particular the dimension between the underside of the foot part and a yarn support of the yarn holding device, specifies the distance between the textile reinforcement, which is formed from the yarn, and the receiving structure. The yarn is at this height after concreting. The height of the twine holding device can be changed, it determines the useful static height of the reinforcement and thus fundamentally influences the load-bearing behavior of the reinforced concrete element.

The twine holding devices remain in the concrete component after concreting. However, in order to be able to detach the receiving structure after concreting and possibly reuse it, a detachable connection can be made between the twine holding device and the receiving structure. Here, too, ultrasonic welding has proven to be advantageous. For this purpose, it has proven to be particularly favorable if at least the head part consists of a thermoplastic material, preferably PLA (polyatic acid).

A water-soluble intermediate layer, which creates a detachable connection between the yarn holding device and the receiving structure, is associated with particular advantages. This is arranged between the receiving structure and the twine holding device and is designed so that the intermediate layer dissolves as a result of the entry of moisture, in particular during concreting, and the connection with the receiving structure is released, so that the connection is only used for transport and securing the position during concreting. According to a preferred embodiment, the foot part has the intermediate layer on its underside, so that it is in two parts and consists of at least two different materials. Particularly preferably, the intermediate layer consists of a weldable material, preferably PVA, polyvinyl alcohol, with which the yarn holding device is welded to the receiving structure, preferably by ultrasonic welding.

The object is also achieved by a reinforcement arrangement, comprising at least one textile reinforcement, formed at least from one yarn. According to the invention, the reinforcement arrangement further comprises the Reinforcement support device, in particular the receiving structure and the yarn holding devices.

If the receiving structure is designed as a thin-walled plate, for example made of metal, wood or plastic, this has proven to be particularly advantageous. The slabs can correspond to the size of the future concrete component and can thus assume dimensions of more than 5 m x 5 m. If the panels are to be transported, it is advisable to divide them into sections. In this case, the sections are connected to each other directly on the formwork before concreting. Detachable click connections have proven to be useful. The receiving structure can contain recesses or the like, which are introduced, for example, in a deep-drawing process or by stamping. According to an alternative embodiment, the receiving structure simultaneously represents part of the formwork. The yarn holding devices and connecting elements which connect the yarn and built-in parts to the receiving structure are attached to the receiving structure.

The reinforcement connected to the receiving structure can be designed as a simple yarn or as a prefabricated scrim. The simple yarn and the prefabricated structure are referred to as yarn in the present description, since the yarn contained in the structure is also held in the yarn holding devices, even if not laid down as a single yarn. The type of filing thus changes with the scrim, since this only has to be laid over the yarn holding devices and connected to them. This alternative method is therefore not described in more detail, but is also covered by the invention, since there is undoubtedly a way for the person skilled in the art to rework this solution.

The reinforcement and the built-in parts are secured in their position. Both when pouring the structure with a concrete matrix, also referred to as concreting below and in the above description, and during transport (within a plant or between plants), the position of the built-in parts and the yarn remains secured relative to the receiving structure. A reinforcement arrangement described in more detail below, consisting of receiving structure, reinforcement and installation parts, is then placed on the formwork and releasably connected to the formwork. The connection can be between the formwork and the receiving structure created by bonding, magnetically or by holding down and maintained during concreting.

The receiving structure can be manufactured or assembled in different sizes. To produce larger components, several receiving structures are used, which are placed next to each other on the formwork. In this case, care must be taken to ensure that the reinforcement has a sufficient lap length to the adjacent reinforcement so that the tensile forces can be transferred in the reinforcement. Tests have shown that an overlap length of 1-5 cm is suitable and sufficient.

Advantageously, the receiving structure has recesses and/or is curved about at least one axis. If a curved formwork is to be used to produce single or multiple curved components, this can be made possible by a special shape of the receiving structure that is able to follow the shape of the formwork.

Further advantages arise when built-in parts such as e.g. B. lines for fluids or electricity, switches, sensors, anchoring elements, transport anchors, electrical sockets, conduits, cables, capillary tubes or the like are arranged by means of a holding device. According to a preferred embodiment, the holding device is constructed in the same way as the yarn holding device, in particular as a plastic holder, detachable and non-detachable. The reinforcement yarn and the necessary built-in parts are connected to the receiving structure in a detachable or non-detachable manner.

According to a first embodiment, the receiving structure is designed for detachment from a concrete part, in which the reinforcement arrangement is concreted, after hardening. The detachment is achieved by means of an intermediate layer. According to a second embodiment, however, the receiving structure is designed to remain in the concrete part as permanent formwork.

A further aspect of the present invention relates to a device for producing a reinforcement arrangement according to the above description, the device comprising at least one robot arm and/or a portal device which has at least one working head which can be moved at least in two dimensions.

According to the invention, the robot and/or the portal device comprise a device for positioning the yarn holding device on the receiving structure and/or a device for yarn laying for connecting the yarn to the yarn holding devices in two or three dimensions. The device for positioning the yarn holding device and/or the device for depositing the yarn for connecting the yarn to the yarn holding devices are arranged on the at least one working head of the robot arm or the portal device. The devices are suitable for connecting the yarn to the yarn holding devices in two or three dimensions for flat and curved surfaces.

An automation unit is used for the automated placement of the yarn. The basis is a robotic arm, a gantry device or a combination of both. As a result, the yarn can be deposited in two or three dimensions. This automated process enables the yarn holding devices to be placed freely on flat and curved surfaces in order to achieve variable axial yarn guidance.

The automation unit also consists of a storage unit that is attached to the working head of the robot arm or the portal device. This in turn includes, among other things, a device for continuous yarn take-off, which supplies the yarn depending on the laying speed and yarn requirement. This can be achieved, for example, by driving the coil body. Furthermore, a subsequent yarn tensioner or yarn store in the form of a compensation device has proven to be very advantageous in the case of continuous depositing processes with different yarn requirements. Alternatively, the yarn feed is made available by means of control technology in comparison to the yarn requirement, i. H. the required twine length is calculated and supplied by the drive unit with a previously defined twine tension for optimal placement. The yarn can be pulled off a spool that is attached directly to the storage unit, to the portal or to an external spool holder. Furthermore, the storage unit includes a connection unit that connects both the yarn holding device to the yarn and the yarn holding device to the receiving structure.

The connections of the yarn holding devices to the receiving structure can be produced, for example, by gluing, screwing, magnetically or by welding. Ultrasonic welding has proven to be particularly advantageous exposed. The yarn holding device is first placed on the surface of the receiving structure. By melting the material by introducing a high-frequency mechanical vibration into the yarn holding device, the material is melted and forms a joint with the receiving structure. Using the same method, the yarn is connected to the yarn holder according to the preferred embodiment. The yarn holding devices are taken from a magazine, which is located directly in the storage unit, or externally, for example from the portal device. In the case of external storage, the yarn holding devices can be fed in, for example, using a hose that serves as a feed.

In order for the yarn to be able to be guided freely, i.e. variably axially, it must be flexible and of low flexural rigidity. The stiffness must be adjusted in such a way that the yarn can be guided around small radii without returning to its original position and without breaking. Despite low rigidity, sufficient load-bearing capacity and safety (durability, heat resistance) must be guaranteed. As a rule, the reinforcement yarn contains a coating (also known as impregnation or impregnation), which contributes to the load-bearing capacity and bondability.

However, this usually also means that the yarn becomes rigid. Reinforcement consisting of a fiber strand made of carbon or glass, which was consolidated (impregnated) in advance, has proven particularly advantageous for variable axial yarn guidance. In a previous production step, a yarn is impregnated with the polymer matrix and prefabricated into a yarn semi-finished product. The required material parameters can thus be optimally set and monitored.

Furthermore, the fiber strand can be adjusted in terms of its geometric properties and its surface can be changed using tools (structuring) or additional process steps (winding with yarn) and the subsequent bond with the concrete can be optimised. The yarn semi-finished product produced in this way is wound up and placed in the reinforcement system for storage as a coil or bobbin.

Furthermore, a thermoplastic polymer matrix has proven to be particularly advantageous as a coating in order to obtain reduced yarn stiffness during laying. Due to the material properties, a reversibly melt or soften consolidated yarn in the subsequent laying process at elevated temperature, as described above. In this way, small depositing radii of less than 5 cm can be achieved. After laying and heating, the yarn has the same properties again and the material parameters are not deteriorated in areas where the yarn was heated. The laying process described with thermal heating of the yarn allows the use of special polymers, which improve the material properties through thermal treatment (heating). As a result of the tempering, i.e. the heating of the yarn material, as well as the activation and conversion of the polymer properties, there is an activation and conversion of the polymer components, which, for example, increases the stiffness of the yarn and/or the bond properties between the individual filaments of the yarn and the yarn with the surrounding concrete matrix can be improved.

It has thus proven to be advantageous for the working head if a heating device for heating a yarn coated or impregnated with a thermoplastic polymer is included, with the result that this softens and becomes malleable and can be laid down in the desired manner with reduced rigidity. The heating device is arranged, for example, on the working head.

The heating device is used in particular when a thermoplastic polymer matrix is used as a coating or impregnation of the yarn. The heating device briefly heats the yarn and the coating to a temperature at which the coating (for example the polymer) softens or melts and the rigidity of the yarn is reduced. This makes it malleable and strong changes of direction can also be made in tight radii. After being laid, the yarn cools down again, which increases its rigidity and guarantees the necessary bond between the yarn and the concrete matrix as well as between the individual filaments of the yarn. This cooling process can be accelerated with an additional cooling unit that can be integrated in a modular manner, as described below.

Further advantages result from a structuring device for producing a surface structure on the softened yarn. Such a local surface structuring to form ribs or the like can also be implemented in the storage unit that has been supplemented by the structuring device. That's what it will be for After heating and converting the yarn into a formable state, it is guided through, for example, a structured pair of rollers or a die as a structuring device, which imparts a structure or profile to the yarn. This acts in the concrete as a form-fitting force transmission between reinforcement and concrete.

Another advantage of the method described is the defined formation of a loop or a shape radius when changing direction at the edge of the component. Due to the heating device and the softening of the yarn, the yarn can be deflected in any radius and laid down endlessly without being severed or cut. The flow of forces within the reinforcement, the yarn, is maintained and the formed loop anchors the reinforcement structure, the yarn, in the edge area.

It has also proven to be advantageous if a cooling device is included, which cools and stiffens the yarn, which has been softened, for example, by heating, after it has been deposited.

1. a. Positionierung und/oder Formung einer Aufnahmestruktur (34),
2. b. Ablegen von Garnhalteeinrichtungen (40, 46, 52, 56, 58) und/oder von Einbauteilen (50) auf der positionierten und geformten Aufnahmestruktur (34), sodass eine Bewehrungsstützeinrichtung (1) gebildet wird,
3. c. Ablegen und Sichern des Garns (32) auf den Garnhalteeinrichtungen (40, 46, 52, 56, 58) in der Reihenfolge, die der vorgesehene Verlauf des Garns (32) für die Bewehrungsanordnung (30) vorgibt. Dabei umfasst das Sichern insbesondere, dass das Garn (32) mit den Garnhalteeinrichtungen (40, 46, 52, 58) verschweißt oder in den Garnhalteeinrichtungen (52) in eine Klickkrone (54), die das Garn (32) am Herausgleiten hindert, eingelegt wird.

The invention is also achieved by a method for producing a reinforcement arrangement according to claim 9. According to the invention, the method comprises the steps:

1. a. positioning and/or shaping of a receiving structure (34),
2. b. Depositing yarn holding devices (40, 46, 52, 56, 58) and/or built-in parts (50) on the positioned and shaped receiving structure (34), so that a reinforcement support device (1) is formed,
3. c. Laying down and securing the yarn (32) on the yarn holding devices (40, 46, 52, 56, 58) in the order which the intended course of the yarn (32) prescribes for the reinforcement arrangement (30). The securing includes in particular that the yarn (32) is welded to the yarn holding devices (40, 46, 52, 58) or placed in a click crown (54) in the yarn holding devices (52), which prevents the yarn (32) from slipping out becomes.

It is advantageous if, in addition, built-in parts are placed on the receiving structure in a subsequent step d).

According to a first alternative, the yarn is welded to the yarn holding devices, it is then not axially displaceable. According to a second alternative, the yarn is placed in a click connection in the yarn holding devices. It can then be moved axially, but the connection can also be established more quickly. The yarn holding devices are preferably designed in such a way that they can be picked up and set down automatically with a storage unit.

The object according to the invention is also achieved by a method for producing a single-curved or multi-curved concrete component. According to the invention, a reinforcement arrangement according to one of claims 10 to 14 is arranged in the concreting mold before concreting. The concrete is then poured and the formwork removed once the concrete has hardened. The receiving structure can either remain in the component or be detached from it. If there are connections and function blocks in the cavities, the receiving structure remains in the concrete component. If it is detached, the reinforcement and the built-in parts remain in the concrete body.

In a modified procedure, the receiving structure is placed directly on the formwork or is already part or the bottom of the formwork. Reinforcement and built-in parts are connected to the receiving structure in the formwork or directly to the formwork using the twine holding devices.

An essential advantage of the invention is the possibility of a variable axial yarn placement by the device, with which a needs-based reinforcement guide can be produced. With the present invention, the yarn material, the reinforcement, in components can be aligned, for example, to the directions of the main stresses caused in the component and the loads can thus be optimally absorbed. Less reinforcement therefore has to be introduced into the component. The variable axial placement is made possible by using the yarn placement devices according to the invention to create a temporary or permanent connection between a receiving structure and a yarn for reinforcement, as well as with capillary tubes, cables, lines or other built-in parts such as anchoring and connecting elements.

Another significant advantage is the possibility of reinforcing single or multiple curved components, as well as the high degree of automation. A high degree of individuality can be achieved with simultaneous series production. This results in economic, ecological and also aesthetic advantages. Another advantage is the ability to transport the entire receiving structure with reinforcement and built-in parts. As a result, a single machine can serve several precast plants, thus reducing investment costs.

• Fig. 1: schematisch eine Ansicht von vorn einer Ausführungsform einer erfindungsgemäßen Vorrichtung zur Herstellung einer Bewehrungsanordnung mit Roboterarm und Komplexarbeitskopf;
• Fig. 2: schematisch eine Seitenansicht einer Ausführungsform einer erfindungsgemäßen Vorrichtung zur Herstellung einer Bewehrungsanordnung mit Roboterarm und Komplexarbeitskopf;
• Fig. 3: schematisch eine Ansicht von vorn einer weiteren Ausführungsform einer erfindungsgemäßen Vorrichtung zur Herstellung einer Bewehrungsanordnung mit Roboterarm und Leichtarbeitskopf;
• Fig. 4: schematisch eine Seitenansicht einer Ausführungsform einer erfindungsgemäßen Vorrichtung zur Herstellung einer Bewehrungsanordnung mit Roboterarm und Leichtarbeitskopf;
• Fig. 5: schematisch eine Ansicht von vorn einer weiteren Ausführungsform einer erfindungsgemäßen Vorrichtung zur Herstellung einer Bewehrungsanordnung mit Portaleinrichtung;
• Fig. 6: schematisch eine Detailansicht einer Ausführungsform eines Leichtarbeitskopfs einer erfindungsgemäßen Vorrichtung zur Herstellung einer Bewehrungsanordnung;
• Fig. 7: schematisch eine Detailansicht einer Ausführungsform eines Komplexarbeitskopfs einer erfindungsgemäßen Vorrichtung zur Herstellung einer Bewehrungsanordnung;
• Fig. 8: schematisch eine perspektivische Ansicht einer Ausführungsform einer erfindungsgemäßen Garnhalteeinrichtung, hier eine Nietgarnhalteeinrichtung;
• Fig. 9: schematisch eine perspektivische Ansicht einer Ausführungsform einer erfindungsgemäßen Garnhalteeinrichtung, hier eine Flachgarnhalteeinrichtung;
• Fig. 10: schematisch eine perspektivische Ansicht einer Ausführungsform eines Kabelhalters;
• Fig. 11: schematisch eine perspektivische Ansicht einer Ausführungsform einer erfindungsgemäßen Garnhalteeinrichtung, hier eine Klickgarnhalteeinrichtung;
• Fig. 12: schematisch eine perspektivische Ansicht einer Ausführungsform einer erfindungsgemäßen Garnhalteeinrichtung, hier eine Umlenkgarnhalteeinrichtung und
• Fig. 13: schematisch eine perspektivische Ansicht einer Ausführungsform einer erfindungsgemäßen Garnhalteeinrichtung, hier eine Temporärgarnhalteeinrichtung.

The invention is explained in more detail below on the basis of the description of exemplary embodiments and their representation in the associated drawings. Show it:

• 1 1: schematically a view from the front of an embodiment of a device according to the invention for the production of a reinforcement arrangement with a robot arm and a complex working head;
• 2 : a schematic side view of an embodiment of a device according to the invention for producing a reinforcement arrangement with a robot arm and a complex working head;
• 3 1: schematically a view from the front of a further embodiment of a device according to the invention for the production of a reinforcement arrangement with a robot arm and a light-duty head;
• 4 : a schematic side view of an embodiment of a device according to the invention for producing a reinforcement arrangement with a robot arm and a light-weight head;
• figure 5 1: schematically a view from the front of a further embodiment of a device according to the invention for producing a reinforcement arrangement with a portal device;
• 6 : a schematic detailed view of an embodiment of a lightweight working head of a device according to the invention for producing a reinforcement arrangement;
• 7 : a schematic detailed view of an embodiment of a complex working head of a device according to the invention for producing a reinforcement arrangement;
• 8 : a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a riveting yarn holding device;
• 9 : a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a flat yarn holding device;
• 10 1: schematically a perspective view of an embodiment of a cable holder;
• 11 : a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a click yarn holding device;
• 12 : a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a deflection yarn holding device and
• 13 : a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a temporary yarn holding device.

1 shows a schematic front view of an embodiment of a device 10 according to the invention for producing a reinforcement arrangement 30 with a robot arm 14 and a complex working head 26. A frame 12 carries a portal device 16, which makes it possible to move the robot arm 14 over the entire base area of the device 10 and to position optimally. The robot arm 14 is articulated and can therefore also act on or over any three-dimensionally shaped base, here a receiving structure 34, which can also serve as formwork, as a concrete form.

For this purpose, the robot arm 14 has a working head, a complex working head 26 in the exemplary embodiment shown, on its end remote from the portal device 16 . This is not only intended to place yarn holding devices, here rivet yarn holding devices 40, on the receiving structure 34 and to form the reinforcement support device 1 and immediately afterwards to deposit yarn 32 (here preferably a towpreg) on the rivet yarn holding devices 40. As a complex working head 26, it has a yarn holder storage 27 (cf 7 ) in which a supply of rivet yarn holders 40 is kept. In addition, the complex working head 26 includes a yarn spool 28 from which the yarn 32 for depositing the textile reinforcement 29 and for forming the reinforcement arrangement 30 is unwound.

At the same time, the illustration indicates the preferred process sequence in which the yarn 32 is laid down immediately after a riveting yarn holding device 40 has been laid down. Alternatively, all required yarn holding devices can also first be attached and then the yarn 32 can be laid down.

2 schematically shows a side view of an embodiment of a device 10 according to the invention for the production of a reinforcement arrangement 30 with a robot arm 14 and a complex working head 26 as well as the other components, such as she already in 1 have been described. The high degree of flexibility in the orientation of the complex working head 26 arranged on the robot arm 14 can be seen. This makes it possible to attach the riveting thread holding devices 40 to the required locations and in the required orientations without any problems even when the receiving structure 34 is deformed about two axes. This makes it possible to produce a reinforcement arrangement 30 which is also able to follow such a heavily deformed receiving structure 34 and enables the production of individually and load-dependently reinforced, multiaxially shaped concrete components.

the Figures 3 and 4 schematically show a view from the front and a side view of a further embodiment of a device 10 according to the invention for the production of a reinforcement arrangement 30 with a robot arm 14 and a lightweight working head 20. In contrast to the device as shown in FIGS Figures 1 and 2 is shown, a light-duty head 20 is used here. In contrast to the complex working head 26, this has no stores for material to be deposited, but rather both the riveting thread holding devices 40 and the thread 32 are fed over the robot arm 14. For this purpose, the corresponding stores, for example the yarn spool 28, are arranged above the portal device 16. The yarn 32 is then fed via a yarn feed 24.

figure 5 shows a schematic view from the front of a further embodiment of a device 10 according to the invention with a portal device 16 for producing a reinforcement support device 1 and then a reinforcement arrangement 30, the robot arm 14 being dispensed with because of the exclusively two-dimensional placement of riveting thread holding devices 40. The complex working head 26 is used, which accommodates the thread spool 28 and also the riveting thread holding devices 40 .

The receiving structure 34 placed completely flat on a work table here is provided with the riveting thread holding devices 40 by the complex working head 26 and subsequently the textile reinforcement 29 for forming the reinforcement arrangement 30 . Here as well as for those previously described Figures 1 to 4 applies that instead of the rivet yarn holding devices 40, other yarn holding devices can also be used, for example those as shown in FIGS Figures 9 to 13 to be discribed.

6 shows schematically a detailed view of an embodiment of a light-duty head 20 of a device according to the invention for producing a reinforcement support device 1 and a reinforcement arrangement 30 by depositing the textile reinforcement 29 on the reinforcement support device 1, which was formed from a receiving structure 34 previously provided with rivet yarn holding devices 40. For this purpose, the light-duty head 20 has a yarn holding feed 22, from which the individual riveting yarn holding devices 40 are also fed from a store. A welding device 23 is provided for connecting it to the receiving structure 34, preferably in the form of a device for ultrasonic welding.

Furthermore, a heating device 25 is arranged in the area over which the yarn 32 is guided within the light-duty head 20 and subsequently deposited on the riveting yarn holding devices 40 . This is used, for example, when the yarn 32 is to be laid in tight radii. The heating of the yarn 32 reduces its stiffness, particularly if it comprises a thermoplastic matrix material, and makes it easier to wrap around tight radii without damage. As soon as the yarn 32 has cooled down again, it resumes its previous rigidity and gives the textile reinforcement 29 or the reinforcement arrangement 30 as a whole the appropriate strength as is required, for example, for the concreting process or transport.

7 shows schematically a detailed view of an embodiment of a complex working head 26 of a device according to the invention for the production of a reinforcement support device 1 and a reinforcement arrangement 30. Neither the riveting yarn holding devices 40 nor the yarn 32 are fed to the complex working head 26, but these materials required for forming the reinforcement arrangement 30 are in the complex working head 26 self-saved. For this purpose, the yarn spool 28 and the yarn holder storage 27 are arranged inside the complex working head 26 . The materials are conveyed as required to the tip pointing towards the receiving structure 34 and processed further there. The welding device 23 is provided for fastening the riveting thread holding devices 40 to the receiving structure 34, with the thread 32 then being deposited over the riveting thread holding devices 40 fastened in this way. As well as to figure 5 described, a heater 25 is provided.

8 shows a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a rivet yarn holding device 40. This has a rivet foot 44 on its lower side in the illustration, which is provided for connection to the receiving structure 34. This is guided through an opening in the receiving structure 34 and then deformed in such a way that the riveting yarn holding devices 40 are fastened to the receiving structure 34 .

On the side facing away from the rivet foot 44, the rivet thread holding device 40 has a thread crown 42 around which the thread can be placed and deflected in different directions in a simple manner. In addition, the yarn can be subsequently fixed or at least secured in the yarn crown 42 by welding the grooves of the yarn crown 42 shut. A sonotrode and the method of ultrasonic welding are also preferably used for this purpose.

9 shows a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a flat yarn holding device 46. While the yarn crown 42 is designed in the same way as the previously described rivet yarn holding device 40, the attachment is provided in a completely different way. Instead of riveting from the rear, planar welding is provided between a flat base 48 and the receiving structure 34 . A hollow-cylindrical sonotrode is preferably used for this purpose, with which the required connection is made using ultrasonic welding.

10 shows a schematic perspective view of an embodiment of a cable holder 50 with which lines or cables laid on the receiving structure 34 can be fixed there. A flat foot 48 is also provided for this purpose, which can be welded to the receiving structure 34

11 shows a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a click yarn holding device 52. This is equipped with a click crown 54 for fixing the yarn 32, which prevents the yarn 32, once it has slipped into the click crown 54, from leaving the click crown 54. In this way, in special cases, for example in the case of a very steep convex shape of the reinforcement arrangement 30, undesired detachment of the yarn 32 can be prevented immediately after placement.

12 shows a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a deflection yarn holding device 56. Similar to the click yarn holding device 52, this provides improved security against the yarn slipping off undesirably by being securely held in the groove 57 of the deflecting yarn holding device 56 after it has been wrapped around it can, at least as long as there is sufficient yarn tension.

13 shows a schematic perspective view of an embodiment of a yarn holding device according to the invention, here a temporary yarn holding device 58. This is particularly suitable if the receiving structure 34 is not to remain on the concrete component as lost formwork, but is to be detached afterwards. Since the twine holding devices generally remain in the concrete component, a separation between these and the receiving structure 34 must be achieved. This is done by a release layer 60, which is water-soluble, for example, and is dissolved by means of water after the concrete component has hardened. Once the release liner 60 is dissolved, the containment structure 34 can be easily peeled away from the concrete member.

Reference List

1

rebar support device

10

Device for producing a reinforcement arrangement

12

frame

14

Robot arm, device for positioning the yarn holding device

16

Portal device, device for positioning the yarn holding device

18

Yarn storage device

20

Light work head, work head

22

Twine Holder Feeder

23

welding device

24

yarn feeder

25

heating device

26

Complex work head, work head

27

twine holder storage

28

thread spool

29

textile reinforcement

30

reinforcement arrangement

32

towpreg, yarn

34

intake structure

40

Rivet thread holding device, thread holding device

42

yarn crown

44

rivet foot

46

Flat yarn holding device, yarn holding device

48

flatfoot

50

Cable holder, built-in part

52

Click yarn holding device, yarn holding device

54

click crown

56

Deflection yarn holding device, yarn holding device

57

groove

58

Temporary yarn holding device, yarn holding device

60

release position

Claims (15)

Reinforcement support device for receiving, holding and deflecting a yarn (32) to form a textile reinforcement (29), the reinforcement support device (1) having yarn holding devices (40, 46, 52, 56, 58) which have at least one of a first side, a top, have a slot that is accessible in at least one direction or at least one slot that is accessible perpendicularly to the top for inserting and/or welding the yarn (32), characterized in that the yarn holding devices (40, 46, 52, 56, 58) have a second side, an underside, are arranged on an at least two-dimensional receiving structure (34) made of a flat material on the surface thereof, the dimension between the surface of the receiving structure (34) and the position of the yarn (32) inserted in the slot being the distance between the receiving structure (34) and the textile reinforcement (29). Reinforcement support device according to claim 1, wherein the twine holding devices (40, 46, 52, 56, 58) at least partially have a rivet foot (44) which can be passed through an opening in the receiving structure (34) at the installation site from a first side of the receiving structure (34 ) are inserted forth and then riveted from a second side, or welded, clamped, glued, screwed or magnetically connected to the receiving structure (34), each temporarily or permanently. Reinforcement support device according to claim 1 or 2, wherein the receiving structure (34) has recesses and/or is curved about at least one axis. Reinforcement support device according to one of the preceding claims, wherein built-in parts (50) are arranged on the receiving structure (34). Reinforcement support device according to one of the preceding claims, wherein the receiving structure (34) is designed, according to a first embodiment, to be detached from a hardened concrete part in which the reinforcement arrangement (30) is concreted, the detachment being carried out by means of a device fixed to the receiving structure ( 34) connected, detachable intermediate layer is achieved, or wherein the receiving structure (34) is designed according to a second embodiment to remain as permanent formwork in the concrete part. Reinforcement support device according to one of the preceding claims, wherein a detachable arrangement is implemented by means of a detachment layer (60) between the receiving structure (34) and the receiving structure (34), so that a temporary yarn holding device (58) can be detached from the receiving structure (34). Reinforcement support device according to Claim 6, in which the release layer (60) is designed to be water-soluble, is dissolved by moisture and detaches from the connection with the receiving structure (34). Reinforcement support device according to claim 7 or 8, wherein the release layer (60) is weldable at least on its side facing away from the temporary yarn holding device (58) and is welded to the receiving structure (34). Reinforcement arrangement (30) comprising at least one textile reinforcement (29) formed from at least one yarn (32), characterized in that the reinforcement arrangement (30) reinforcement support device (1) according to one of Claims 1 to 8 and the inserted one, to form a reinforcement arranged yarn (32). Device for producing a reinforcement arrangement (30) according to Claim 9, comprising at least one robot arm (14) and/or a portal device (16) which have at least one working head (20, 26) which can be moved at least in two dimensions, characterized in that the robot arm (14 ) and/or the portal device (16) comprises a device for positioning the twine holding devices (40, 46, 52, 56, 58) on the receiving structure (34) and a device for twine deposit, the device for positioning the twine holding devices (40, 46 , 52, 56, 58) on the receiving structure (34) and/or the device for depositing the yarn on the at least one working head (20, 26) of the robot arm (14) and/or the portal device (16). Apparatus according to claim 10, comprising heating means (25) for heating a yarn (32) coated or impregnated with a thermoplastic polymer, thereby softening and making it malleable. Apparatus according to claim 10 or 11, comprising a structuring device for producing a surface structure on the softened yarn (32). Apparatus according to any one of claims 10 to 12, including cooling means for cooling and stiffening the softened yarn (32) after deposition. Method for producing a reinforcement arrangement according to claim 9, characterized in that the method comprises the steps: a. positioning and/or shaping of a receiving structure (34), b. Depositing yarn holding devices (40, 46, 52, 56, 58) and/or built-in parts (50) on the positioned and shaped receiving structure (34), so that a reinforcement support device (1) is formed, c. Laying down and securing the yarn (32) on the yarn holding devices (40, 46, 52, 56, 58) in the order which the intended course of the yarn (32) prescribes for the reinforcement arrangement (30). Method for producing a single or multiple curved concrete component in a formwork, characterized in that before concreting a reinforcement arrangement (30) according to claim 9 is arranged in the formwork or a receiving structure (34) forms the formwork at least partially.

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