EP4135957A2

EP4135957A2 - Manufacturing system for additive production of components, and method

Info

Publication number: EP4135957A2
Application number: EP21722755.2A
Authority: EP
Inventors: Hendrik Lindemann; Roman Gerbers; Niklas Nolte; Alexander Türk
Original assignee: Aeditive GmbH
Current assignee: Aeditive GmbH
Priority date: 2020-04-16
Filing date: 2021-04-12
Publication date: 2023-02-22
Also published as: WO2021209090A3; DE102020110431A1; WO2021209090A2; CN115397637A; US20230147930A1; JP2023521435A

Abstract

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

Description

Manufacturing system for the additive manufacturing of components and processes

The invention relates to a production system for the generative production of components, in particular for carrying out an injection molding process for the generative production of components, a method for the generative production of a component, in particular with an injection molding process, and a method for building a production system.

Manufacturing systems are known in principle. For example, they can include different processing machines and handling systems in order to manufacture components, in particular in series. The disadvantage of known manufacturing systems is their low flexibility.

Today's manufacturing systems for the additive manufacturing of components, in particular of concrete components, require a high level of manual effort, for which specially trained specialists are required. Since there is already a shortage of skilled workers, particularly in the construction industry, or is emerging in many countries, it is necessary to automate the process for manufacturing components. In addition, there may be quality defects in the components, as human errors can reduce the quality.

In addition, the known production systems for the production of components, in particular for the additive production of concrete components, are inflexible. These manufacturing systems are usually embedded in an existing factory structure. Since the requirements for a manufacturing system change in ever shorter cycles, there is a need in the construction industry, for example, to use a flexible manufacturing system. In addition, it can be preferred that this flexibility also offers the possibility of producing concrete components on or near the construction site. However, today's production systems cannot be relocated to a construction site, so that the concrete components are produced in the production system embedded in the factory and then transported from the production system to the construction site. The generative production of components regularly comprises the mixture of two or more material components, this mixture often being provided as a material component mixture.

Mixtures of material components can be made available for concrete components or ceramic components, for example. At present, for example, concrete components that are manufactured using an additive manufacturing process are usually manufactured using a concrete component mixture that has been dry-premixed in the factory. The concrete component mix is made available to a component manufacturer who uses a generative manufacturing process, but this can only have a limited or no influence on the composition of the concrete component mix.

It is therefore an object of the present invention to provide a production system for the generative production of components, in particular for carrying out an injection molding process for the generative production of components, a method for the generative production of a component, in particular with an injection molding process, and a method for setting up a production system, which reduce or eliminate one or more of the disadvantages mentioned. In particular, it is an object of the invention to provide a solution which enables the automated production of individual concrete components. At least one object of the invention is to provide an alternative manufacturing system and method.

According to a first aspect, the aforementioned object is achieved by a production system for the generative production of components, preferably concrete components, in particular for carrying out a spraying process, preferably a shotcrete process, for the generative production of components, preferably concrete components, comprising a first production module with a mixing unit to produce a composite material, preferably a concrete, in particular by mixing a first material component, preferably a first concrete component, and a second material component, preferably a second concrete component, and a second production module with a first handling unit for the generative production of a component with the composite material, preferably one Concrete component with the concrete, in particular for the production of a sprayed component, preferably a sprayed concrete component, the first production module and the second production module being coupled by means of a conveyor unit.

The invention is based on the knowledge that existing production systems for the generative production of components, in particular of concrete components, are inflexible. In addition, multi-part manufacturing systems have not been successful in the past because the interfaces between the multiple parts of these manufacturing systems have resulted in quality and productivity losses. The invention was based on the knowledge that the two production modules, with one production module comprising the mixing unit and the other production module comprising the handling unit for the generative production of the component, in particular the concrete component, offer a division that such interface problems essentially do not occur. It was also found that such a division makes it possible to produce components, in particular concrete components, in particular with a shotcrete process, which are technically superior to those components that have been conventionally produced.

The first production module with the mixing unit enables the composite material to be provided. The mixing unit can also have load cells, in particular be mounted on load cells, so that the material components can be weighed by means of the mixing unit. A composite material is understood to mean, in particular, a material that has at least two material components. The composite material is produced in particular by mixing the first material component with the second material component. The composite material can be concrete, for example. In the following, the production system and the processes are described, particularly in connection with the production and processing of concrete. However, the following explanations are also to be understood in an analogous manner for the production and processing of other composite materials. The mixing unit is in particular for producing a concrete with a hydraulic binder, an alkaline-activated binder and / or a Geopolymer binder formed. Concrete is to be understood in particular as the still young, workable concrete. The concrete is produced in particular by mixing the first concrete component and the second concrete component with one another. The concrete component can, for example, be an aggregate, a mixing water, concrete additives and / or a hydraulic binder such as cement and / or an alkaline-activated binder and / or a geopolymer binder and / or

Be concrete admixtures. The concrete admixtures can be solid or liquid, for example. The second production module comprises the first handling unit. The first handling unit is arranged and designed to generatively produce a component, preferably a concrete component, with the composite material, preferably the concrete. A concrete component is also understood to mean a reinforced concrete component, among other things. In particular, the first handling unit is arranged and designed to produce a shotcrete component, preferably using a shotcrete method. The first handling unit preferably has a spray nozzle which is set up to spray concrete. The first handling unit is also preferably designed in such a way that the spray nozzle can be moved in at least three spatial directions. In addition, the first handling unit preferably has feed lines for concrete and / or for compressed air and / or for one or more additives and / or control lines for controlling sensors and actuators.

The concrete to be processed in the second production module with the first handling unit is produced in the first production module in the mixing unit. So that this produced concrete is available to the first handling unit, the first production module is coupled to the second production module by means of the conveyor unit. The conveying unit is in particular a unit for conveying flowable materials. The conveyor unit is in particular arranged and designed to bring the composite material, in particular the concrete, from the first production module to the second production module. The delivery unit can be, for example, a hose, a pipe and / or a concrete delivery component. Coupled to one another is in particular in such a way understand that the concrete can be brought, in particular conveyed, from the first production module to the second production module.

In a preferred embodiment variant of the manufacturing system, it is provided that the first manufacturing module and the second manufacturing module are designed separately from one another. The separate design of the first manufacturing module and the second manufacturing module means in particular that they are not designed integrally. Furthermore, this can mean that the first production module and the second production module are each designed as a unit. It is particularly preferred that the first production module and the second production module can be transported and / or set up separately from one another.

Such a design of the first production module and the second production module achieves various advantages. The different production modules can be produced separately from one another. This results in advantages in the production process for producing the first production module and the second production module, since only the interfaces have to be coordinated with one another.

In addition, the production modules can be provided as compact units that can be transported on a commercial truck, for example. The first manufacturing module and the second manufacturing module can thus be transported independently of one another and, for example, transported to a construction site.

In addition, the setup of the first production module relative to the second production module can be varied in a simple manner. This can be advantageous, for example, if the production system is used in a factory and the production equipment is rearranged there, so the individual production modules of the claimed production system can simply be shifted, with only the conveyor unit acting as an interface being adapted if necessary. In addition to the conveyor unit, other elements can also act as an interface between the first production module and the second production module act, for example control lines and compressed air lines.

In a further preferred embodiment of the manufacturing system, it is provided that the first manufacturing module has a supply unit for providing the first material component, preferably the first concrete component, and / or the second material component, preferably the second concrete component, the supply unit preferably having a first supply module for providing the having a first material component and a second supply module for providing the second material component.

The first supply module and / or the second supply module can be designed as a silo, for example. The first supply module and / or the second supply module can be filled, for example, with a big bag, a crane system, a wheel bearing and / or an industrial truck and / or a conveyor belt.

In addition, the first production module can have a conveying device which conveys a material component located on the conveying device, preferably a concrete component, to the mixing unit. For example, the first production module can have a receiving area for a concrete component, in particular an aggregate, in particular an opening. The concrete component can reach the conveying device through this opening and be conveyed to the mixing unit. The supply unit is preferably arranged vertically above the opening. The receiving area can, for example, be coupled to a silo for storing the concrete component, in particular to a screw conveyor system or a conveyor belt. In addition, the silo can also be coupled directly to the mixing unit via a screw conveyor system or a conveyor belt.

Another preferred development of the manufacturing system is characterized in that the first manufacturing module comprises a pump unit, wherein a vibration unit is preferably arranged between the mixing unit and the pumping unit, and / or the pumping unit has the or a vibration unit.

The pump unit is preferably arranged and designed in such a way that it can be removed from the first production module. For example, the pump unit can be arranged on a rail unit which is set up so that the pump unit can be removed from the first production module.

The vibration unit is preferably arranged and designed to improve the flow of the concrete produced between the mixing unit and the pumping unit and / or to improve the slipping of the concrete in a holding tank of the pumping unit. In particular, the vibration unit is intended to prevent concrete from building up in front of and / or in the pumping unit and possibly clogging the path between the mixing unit and the pumping unit and / or the path from the pumping unit to the delivery unit. The vibration unit or the vibration units can, for example, be driven electrically or pneumatically.

In addition, it is preferred that the production system comprises a fresh water reservoir, it being particularly preferred that this is coupled to a unit for water temperature control.

In a further preferred embodiment of the manufacturing system, it is provided that the first manufacturing module has a cleaning system for automated cleaning, in particular the mixing unit, the pump unit, an application unit, in particular the spray nozzle, auxiliary units and / or hoses, the cleaning system preferably having a fluid pump for Has removal of a cleaning fluid and preferably the cleaning system is designed to be fed with treated water and / or to treat water. The cleaning system, in particular the pump unit and / or the mixing unit, can, for example, have cleaning fluid nozzles through which cleaning fluid can exit. In the event that there is essentially only concrete residues in the mixing unit or the Pump unit are located, they can be cleaned by means of cleaning fluid that emerges from the cleaning fluid nozzles.

It is preferred that the cleaning system has a cleaning control which is set up to control the cleaning fluid nozzles with a predefined cleaning sequence. In addition, it can be preferred that the cleaning control is designed to determine the predefined cleaning sequence, in particular on the basis of output signals from sensors. The sensors are preferably set up to provide the output signals, the output signals representing a degree of contamination in a sensor monitoring area. The production system can also have sensors for monitoring fill levels.

In a further preferred embodiment of the manufacturing system, it is provided that the first manufacturing module has a first metering unit and / or weighing unit which is or are set up to set a component-specific mixing ratio between the first material component and the second material component. In particular in combination with the second metering unit and weighing unit explained in more detail below, this embodiment variant has particular advantages. Systems known up to now for the generative production of concrete components generally use a premixed material compound which is only mixed with water and / or other additives at the production site, so that a usable concrete is produced. However, this previously used solution has various disadvantages. Concrete components differ in terms of their geometry and size, so that different material properties are required for their manufacture. For example, while the material for a support has to solidify or harden very quickly so that a great height can be reached in a short time, a material for a widespread, flat application, for example a wall, should solidify or harden more slowly, since the crossing times of the material applying Handling unit are longer. If a material solidifies too quickly, there is a danger a poor bond and thus a structurally built-in predetermined breaking point between the successive layers of material.

As a result, a finished, premixed material compound is limited in the range of components that can be covered. In addition, this results in high material costs in order to bring the large quantities of material required to different destinations. By providing a supply unit, possibly with a first supply module and a second supply module and possibly further supply modules and corresponding metering units or weighing units, a concrete component mix that meets the requirements can be produced from different concrete components. This concrete component mixture can in particular be mixed individually for each concrete component to be produced, so that the different material properties mentioned above are achieved in each case. This applies analogously to the provision of other composite materials that comprise at least two material components.

Another preferred development of the manufacturing system is characterized in that the second manufacturing module has a second handling unit for carrying out support processes, in particular for reworking the composite material, for inserting reinforcement elements and / or for inserting component components and / or for integrating components for securing purposes of component transport. These structural components can be, for example, slabs, paving stones, brick slips, windows, doors and / or empty pipes. Components for transport can be, for example, transport anchors, threads for attaching anchors or equivalent solutions. The second handling unit can in particular be arranged and designed to arrange a positioning element and / or a reinforcement unit. The reworking can in particular be or include a surface reworking.

It is further preferred that the first handling unit and the second handling unit interact in such a way that they can carry out a method comprising: producing a first concrete layer and a second Concrete layer with a generative method, preferably with a shotcrete method, in particular by the first handling unit, arranging a positioning element for arranging a reinforcement unit, wherein the positioning element is arranged with a support section between the first concrete layer and the second concrete layer and with a fastening section from the first concrete layer and protrudes from the second concrete layer, in particular with the second handling unit, arranging at least one reinforcement unit for reinforcing the concrete component on the positioning element, in particular with the second handling unit, and preferably creating a concrete cover layer on the first concrete layer and the second concrete layer in such a way that the reinforcement unit in Is essentially covered with concrete, in particular by the first handling unit.

The first handling unit can be designed as a first robot and / or the second handling unit can be designed as a second robot. The first robot and / or the second robot can, in particular, be designed as an articulated arm robot. It is particularly preferred that a distal end of the robot or robots is designed to be movable in three spatial directions. The first handling unit and / or the second handling unit preferably each have an active area in which they can carry out a production process, in particular a spraying process, preferably a shotcrete process, and / or a support process with a tool.

Another preferred development of the manufacturing system is characterized in that the second manufacturing module comprises a turntable for rotating the component. The turntable can, for example, be located next to the first handling unit and next to the second handling unit. In particular, it is preferred that the turntable is arranged between the first handling unit and the second handling unit. A further axis is integrated into the production system through the turntable, so that the geometric freedom is further increased. The turntable preferably has an axis of rotation which is oriented essentially vertically during operation. In addition, the turntable can have one, two or more pivot axes, so that the axis of rotation has a vertical and a horizontal component. In order to further increase the flexibility of the manufacturing system, it can be preferred that the manufacturing system has a second, external turntable. The second turntable is preferably arranged next to the second production module and can be reached by an external operator, for example with an industrial truck. Furthermore, it is preferred that the second production module comprises a first tool changing system for exchanging tools used by the first handling unit and / or the second handling unit. It is preferred that the tool change system can be reached by an operator from an external side of the production system in order to change the tools and / or to service them. In addition, it can be preferred that the second production module comprises a second tool change system, wherein the first tool change system is preferably designed to exchange tools used by the first handling unit and / or the second tool change system is designed to exchange tools used by the second handling unit.

In a further preferred embodiment variant of the manufacturing system, it is provided that the first handling unit and / or the second handling unit is or are arranged in a flexible manner. Locally flexible means in particular that the first handling unit and / or the second handling unit can move relative to a base body of the second production module and in particular relative to a workpiece to be machined, in particular a component or concrete component.

In particular, it can be preferred that the first handling unit and / or the second handling unit is or are arranged on a linear axis. The first handling unit and / or the second handling unit is or are preferably coupled to a drive, preferably in each case, so that the first handling unit and / or the second handling unit can be moved relative to the linear axis or axes.

In addition, it can be preferred that the first handling unit and / or the second handling unit has or have at least one multi-axis positioning system, the multi-axis positioning system being set up so that the first handling unit and / or the second handling unit can be moved or moved in at least two spatial directions . are. The multi-axis positioning system can, for example, be designed as a lifting and rotating unit or comprise one. In a further preferred embodiment of the manufacturing system, it is provided that the second manufacturing module has at least two, preferably three, separate sub-modules, a first sub-module having the first handling unit and / or a second sub-module having the second handling unit and / or a third sub-module having the turntable, wherein at least two of the sub-modules are designed so that they can be transported separately from one another. It is particularly preferred that the third sub-module can be arranged between the first and the second sub-module. In addition, it is preferred that the second production module has a fourth sub-module, the fourth sub-module having the second turntable. The second sub-module is preferably arranged adjacent to the third sub-module, in particular such that a workpiece can be moved from the fourth sub-module to the third sub-module.

In a further preferred embodiment it is provided that the manufacturing system comprises a component transport system which is arranged and designed to feed components to the first handling unit and / or the second handling unit. The component transport system can be set up, for example, to move pallets, in particular steel pallets, from an area outside the second production module into the second production module, so that a component arranged on a pallet can be moved in an active area of the first handling unit and / or the second handling unit. The component transport system can, for example, a variety of Have transport rollers which are arranged and designed to convey the pallets, in particular to convey them linearly.

The component transport system and the second manufacturing module are preferably arranged and designed such that pallets and / or components can be moved into the second manufacturing module on a first side of the second manufacturing module and out of the second manufacturing module again on the first side of the second manufacturing module. Alternatively or in addition, the component transport system and the second production module are preferably arranged and designed in such a way that pallets and / or components are moved into the second production module on one or the first side of the second production module and on a second side of the second opposite the first side Manufacturing module can be moved out of the second manufacturing module.

In a further preferred embodiment variant, it is provided that the first sub-module, the second sub-module and / or the third sub-module is or are designed to vary, in particular to increase, a clear height of the interior space (s).

The first sub-module, the second sub-module and / or the third sub-module preferably have a lifting unit, in particular each, which is or are arranged and designed, the clear height of the interior space (s) of the first sub-module, the second sub-module and / or the third sub-module, in particular in that the roof or roofs and / or one or more side walls of the first sub-module, the second sub-module and / or the third sub-module can be raised. In addition, it can be provided that at least one side wall of the sub-modules, preferably two side walls of the sub-modules, are designed to be removable. For example, the third sub-module with the turntable can be arranged between the first sub-module and the second sub-module. In order to be able to process a concrete component arranged on the turntable, it is preferred that the side walls of the third sub-module that of the first Part module and facing the second part module can be removed. In addition, it is preferred that the side walls of the first sub-module and of the second sub-module, which face the turntable, are designed to be removable. In a further preferred embodiment of the manufacturing system, it is provided that it comprises a third manufacturing module with a charging unit for the provision of material components, which are in particular additives, preferably powdery, fibrous and / or liquid additives, and / or additives and / or binders, wherein the charging unit preferably comprises a feeding device and a conveying unit and / or a second metering unit.

The third production module can form a unit with the first production module. However, it is particularly preferred that the third production module is designed separately from the first production module, in particular that it can be transported and / or set up separately. The feeding device can, for example, be a silo, in particular a pneumatically fillable silo, a bag receiving station, also called a big bag station, or a

Be a bag infeed station. The binders can in particular be mineral and / or alkaline-activatable binders and / or geopolymer-based binders. It is particularly preferred that the third production module is intended to provide additives, additives and binders. In particular, it is then preferred that the first production module is essentially intended to provide aggregates.

Another preferred embodiment variant of the manufacturing system is characterized in that the third manufacturing module comprises a second weighing unit which is set up to weigh and / or dose binding agents. Furthermore, the third production module can comprise a further weighing unit in order to weigh and / or dose additives and / or additives. In addition, it can be preferred that the third production module comprises further metering units and further weighing units which are set up to meter additives and additives. In an even more preferred one It is provided that the third production module comprises a coolant system for cooling the concrete. The coolant system for cooling the concrete can in particular be a flake ice system for producing and / or providing ice for cooling the concrete. Furthermore, it is preferred that the coolant system is designed to provide ice to the pump unit. The ice can also be used to clean the pump unit.

Another preferred development of the manufacturing system is characterized in that the first manufacturing module, the second manufacturing module, the third manufacturing module and / or one, several or all of the sub-modules have a housing and / or as a transport unit, for example a container, in particular a 10 Foot and / or 20 foot and / or 40 foot container, is or are, wherein preferably side walls of the housing are at least partially openable. In addition, it is preferred that the side walls, floors and / or ceilings of the housing (s) have sound and / or heat insulating material. The sound and / or heat insulating material can for example be a mineral wool. The side walls, floors and / or ceilings can for example be provided with the mineral wool and covered with a fleece and / or a perforated metal sheet. In addition or as an alternative, an insulating foam can also be sprayed on and / or insulating mats can be arranged.

In a further preferred development of the manufacturing system, it is provided that the roofs and / or side walls are designed to be liftable and are preferably coupled to a further lifting mechanism. In a further preferred embodiment it is provided that the first production module, the second production module, the third production module and / or one, several or all of the sub-modules have a first floor and a second floor spaced apart in the vertical direction to form a gap between the first floor and the has or have a second floor, wherein a drainage channel for the disposal of cleaning fluid is preferably set up in the intermediate space. The cleaning fluid can for example fluid, in particular water, composite material, in particular concrete, and dirt particles.

In a further preferred embodiment it is provided that the production system has a material separation device, in particular a concrete separation device, which is set up to separate the composite material from a cleaning fluid or the cleaning fluid. It is preferred that the material separation device acts in the drainage channel. The material separation device has the advantage that composite material residues, in particular concrete residues, can be reused and thus the efficiency and environmental compatibility are increased. The material separation device can for example be arranged between the first base and the second base.

The first floor is preferably a work surface that faces the concrete component during operation. The second floor is preferably arranged vertically under the first floor during operation. In the intermediate space formed between the first floor and the second floor, further devices of the manufacturing system can be arranged, for example also the conveyor unit, electrical lines and / or further supply devices.

According to a further aspect, the aforementioned object is achieved by a method for the generative production of a component, preferably a concrete component, in particular using a spraying method, preferably a shotcrete method, comprising the steps of: providing a first material component, preferably a first concrete component, and a second material component , preferably a second concrete component, in particular on a supply unit of a production system, generating a composite material, preferably a concrete, by mixing the first material component, preferably the first concrete component, and the second material component, preferably the second concrete component, in particular in a mixing unit of the production system, and Generative production of the component with the composite material, preferably the concrete component with the Concrete, preferably by means of a spraying process, further preferably by means of a sprayed concrete process, in particular with a first handling unit.

In a preferred embodiment of the method it is provided that this comprises the step: metering the first material component, preferably the first concrete component, and the second material component, preferably the second concrete component, in a component-specific mixing ratio. It is also preferred that a third and / or further material component, in particular concrete components, are also dosed, so that a component-specific component mixture is produced. It is further preferred that the method comprises the step: shaking and / or pumping the composite material, preferably the concrete, from the mixing unit to the first handling system. In addition, it can be preferred that the method comprises the step: reworking the component, preferably the concrete component, inserting a reinforcement element and / or inserting structural components. The component can be reworked, for example, by means of smoothing and / or milling tools.

In a further preferred embodiment variant of the method it is provided that it comprises the step: moving a workpiece and / or a pallet into an effective area of the first handling system and / or the second handling system. The workpiece and / or the pallet is preferably moved linearly into the effective area. Furthermore, the workpiece and / or the pallet is preferably moved into the active area on a first side of the active area and moved out of the active area on a second side of the active area arranged opposite the first side.

According to a further aspect, the above-mentioned object is achieved by a method for setting up a production system for the generative production of components, preferably concrete components, in particular for carrying out a spraying process, preferably a shotcrete process, for the generative production of components, preferably concrete components, comprising the steps of: providing a first production module with a mixing unit for producing a composite material, in particular a concrete, based on material components, preferably concrete components, in particular by mixing a first material component, preferably a first concrete component, and a second material component, preferably a second concrete component , Provision of a second production module with a first handling unit for the generative production of a component with the composite material, preferably a concrete component with the concrete, in particular for the production of a sprayed component, preferably a shotcrete component, and coupling the first production module and the second production module in such a way that the Composite material produced in the mixing unit, preferably the concrete produced in the mixing unit, can be brought to the first handling unit.

In particular, the coupling of the first production module and the second production module takes place in such a way that waste water that occurs during the production of the component can be discharged from the drainage channel. In addition, the coupling can take place in such a way that control and / or compressed air lines are connected.

The methods and their possible further developments have features or method steps which make them particularly suitable for being used for a production system described above and its further developments.

For further advantages, design variants and design details of the further aspects and their possible further developments, reference is also made to the description given above for the corresponding features and further developments of the manufacturing system.

Preferred exemplary embodiments are explained by way of example with the aid of the accompanying figures. Show it:

FIG. 1: a schematic, three-dimensional view of an exemplary embodiment of a manufacturing system; FIG. 2: a transparent view of the manufacturing system shown in FIG. 1;

FIG. 3: a further schematic, three-dimensional view of an exemplary embodiment of a manufacturing system; FIG. 4: a schematic, two-dimensional side view of the manufacturing system;

FIG. 5: a schematic representation of a method for the generative production of a concrete component; and

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

Identical or essentially functionally identical or similar elements are provided with the same reference symbols in the figures.

FIG. 1 shows a manufacturing system 1 with a first manufacturing module 100, a second manufacturing module 200 and a third manufacturing module 300, a peripheral module 400 being additionally provided. The first production module 100 has a first supply module 102 and a second supply module 104 shown in FIG. 2, through which a concrete component, in particular a granulate, can be brought into the first production module 100. The second production module 200 has a first sub-module 210, a second sub-module 220 and a third sub-module 230. The sub-modules 210, 220, 230 are designed to be vertically extendable. The sub-modules 210, 220, 230 are each a 20-foot container, each of which has a lifting system with which the roofs and side walls of the sub-modules 210, 220, 230 can be raised.

The inner workings of the three modules 100, 200, 300 are shown in particular in FIG. To produce the concrete component with the concrete, the second production module 200 has a first handling unit 212. The first sub-module 210 also has a tool changing system 214 in which, for example, different spray nozzles for the handling unit 212 can be stored. Furthermore, the second production module 200 has a second Handling unit 222, which is desolated in the second sub-module 220. The third sub-module 230 arranged between the first sub-module 210 and the second sub-module 220 has a turntable 232. The concrete component is generated generatively on the turntable 232, in particular by means of a shotcrete method.

By means of the first supply module 102 and the second supply module 104, a concrete component or a plurality of concrete components can get into the first production module 100. In the present case, these modules 102, 104 are designed as grids, over which, for example, the concrete component can be tipped out or, for example, can be provided in the form of a silo. The concrete component can pass from the supply modules 102, 104 to a mixing unit.

In addition, the production system 1 has the third production module 300, which has charging units 302 and a second metering unit 304. The charging units 302 are provided in particular for storing additives, additives and binding agents for the concrete to be produced. The second metering unit 304 coupled to the charging units 302 can measure a weight or a volume or a quantity of the additive or the binding agent and send it to the mixing unit 106 located below as required. In the mixing unit 106, these additives and binders are mixed with the concrete components, in particular granules, supplied via the supply modules 102, 104.

The production system 1 further comprises a peripheral unit 400. The peripheral unit 400 comprises units for carrying out support processes. The peripheral unit 400 can, for example, have an air pressure unit for providing compressed air. In addition, the peripheral unit 400 can comprise a wastewater treatment plant. Furthermore, it can be preferred that the peripheral unit 400 has a power unit which is arranged and designed to supply the manufacturing system with electrical power. As a result, the manufacturing system can be operated autonomously and is particularly advantageous for use close to construction sites. In addition, the peripheral unit 400 can include a reinforcement bending unit which is arranged and designed to shape reinforcements, in particular reinforcing bars, in a component-specific manner.

FIG. 3 shows another embodiment of the manufacturing system 1. In particular, the manufacturing system 1 differs from the manufacturing system described above in that the first handling unit 212 and the second handling unit 222 are each arranged on a linear axis 214, 224. As a result of this arrangement, the handling units 212, 222 can move in the direction of the linear axes 214, 224. As a result, the processing space is enlarged so that larger concrete components can be produced with the first handling unit 212. In addition, instead of the turntable 232 described above, a linear table 234 is provided. The linear table 234 can be moved in the same direction as the handling units 212, 222. Components can thus be moved into the production system 1 in a simple manner. In addition, even larger components can be produced by moving the linear table 234 in a targeted manner.

The interior of a first production module 100 is shown in FIG. A concrete component, in particular a rock granulate, can reach the conveyor belts 130, 132 through the supply modules 102, 104. The concrete component is conveyed into the mixing unit 106 by means of the conveyor belts 130, 132. The third production module 300, which has the loading units 302, is arranged vertically above the mixing unit 106. By means of the charging units 302 and the second metering unit 304, further concrete components, in particular binders and additives, are brought into the mixing unit 106 in a targeted manner. In the mixing unit 106, the different concrete components are usually mixed with one another with water, so that a concrete is produced. From the mixing unit 106, the concrete reaches a pump unit 110 via an ejection funnel 108. A conveying unit 112, which couples the first production module 100 to the second production module 200, is arranged on the pump unit 110. The first production module 100 also has a cleaning system 114. The cleaning system 114 is coupled to cleaning nozzles 116 in the mixing unit 106 and to cleaning nozzles 118 in the discharge funnel 108 and the pump unit 110. These are also coupled to a fresh water line 129. The mixing unit 106, the discharge funnel 108 and the pump unit 110 are cleaned by the fluid, in particular water, emerging from the cleaning nozzles 116, 118. This cleaning is used in particular when there is essentially no concrete to be processed in these units. The water contaminated with cleaning particles, in particular concrete residues, is disposed of via a waste water valve 120 and a waste water pump 122. Disposal takes place via a gray water pipe 126 which passes through a water treatment system 124. From the water treatment 124, the purified water reaches the cleaning system 114 again via a white water line 128. From the cleaning system 114, the water can get back into the cleaning circuit described above.

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

In step 502, a concrete is created by mixing the first concrete component and the second concrete component. This mixing takes place in particular in a mixing unit 106 of the production system 1. In step 504, a concrete component is produced generatively with the previously produced concrete. This additive manufacturing of the concrete component takes place in particular by means of a shotcrete method, in particular with a first handling unit 212.

Steps 500, 502, 504 can each include further steps or further steps can take place between, before and / or after these steps, which are described below. In step 506, a first concrete component and a second concrete component are dosed in a component-specific mixing ratio. In step 508 the concrete is then vibrated and / or pumped from the mixing unit to the handling system. In step 510, the concrete component is reworked, a reinforcement element is inserted and / or component components are inserted.

FIG. 6 shows a method for setting up a production system 1 for the additive manufacture of concrete components, in particular for carrying out a shotcrete method for the additive manufacture of concrete components. In step 600, a first production module 100 with a mixing unit 106 for producing a concrete based on concrete components is provided. The concrete is produced with the mixing unit in particular by mixing a first concrete component and a second concrete component.

In step 602, a second production module 200 with a first handling unit 212 for the generative production of a concrete component with the concrete is provided. In particular, the first handling unit 212 is arranged and designed to produce a shotcrete component.

In step 604, the first production module 100 and the second production module 200 are coupled to one another, in particular in such a way that the concrete produced in the mixing unit 106 can be brought to the first handling unit 212.

The manufacturing system 1 described above has the particular advantage that it comprises a plurality of manufacturing modules 100, 200, 300 which are set up in such a way that a modular structure of the manufacturing system 1 leads to surprisingly high-quality components. This is made possible in particular by the skillful selection of the distribution of the components provided in the production modules 100, 200, 300, in particular the mixing unit 106 and the handling units 212, 224.

In addition, the production system 1 enables the on-site mixing of concrete component mixes, in that the production system 1 connects the supply modules 102, 104 and the charging units 302 with the second Has metering unit 304, so that several concrete components can be mixed with one another in a component-specific manner and therefore no prefabricated concrete component mixtures are required.

The production system 1 also enables a flexible structure in a production hall, on a construction site or in an area close to the construction site due to the construction with three separate production modules 100, 200, 300. The arrangement shown in the figures can be changed by adapting the interfaces so that the manufacturing system can be adapted flexibly.

REFERENCE LIST

Manufacturing system, first manufacturing module, first supply module, second supply module

Mixing unit

Discharge funnel

Pumping unit

Delivery unit

Cleaning system

Cleaning nozzles

Waste water valve

Dirty water pump

Water treatment

Gray water pipe

White water pipe

Fresh water line, first conveyor belt, second conveyor belt, second production module, first sub-module, first handling unit

Tool change system first linear axis second sub-module, second handling unit, second linear axis, third sub-module

Turntable

Linear table, third production module, loading units, second dosing unit, peripheral module, external turntable

Claims

PATENT CLAIMS

1. Production system (1) for the generative production of components, preferably concrete components, in particular for carrying out a spraying process, preferably a shotcrete process, for the generative production of components, preferably concrete components, comprising a first production module (100) with a mixing unit (106) for Production of a composite material, preferably a concrete, in particular by mixing a first material component, preferably a first concrete component, and a second

Material component, preferably a second concrete component, and a second production module (200) with a first handling unit (212) for the generative production of a component with the composite material, preferably a concrete component with the

Concrete, in particular for producing a sprayed concrete component, preferably a sprayed concrete component, the first production module (100) and the second production module (200) being coupled by means of a conveying unit (112).

2. Manufacturing system (1) according to claim 1, wherein the first manufacturing module (100) and the second manufacturing module (200) are formed separately from one another, and in particular the first manufacturing module (100) and the second manufacturing module (200) can be transported and / or separately from one another are designed to be set up.

3. Manufacturing system (1) according to one of the preceding claims, wherein the first manufacturing module (100) has a supply unit (102, 104) for provision of the first material component, preferably the first concrete component, and / or the second material component, preferably the second concrete component, the supply unit (102, 104) preferably having a first supply module (102) for providing the first material component and a second supply module (104) for

Having providing the second material component.

4. Manufacturing system (1) according to one of the preceding claims, wherein the first manufacturing module (100) comprises a pumping unit (110), a vibration unit and / or the pumping unit preferably being arranged between the mixing unit (106) and the pumping unit (110) which has a vibration unit and / or a cleaning system (114) for automated cleaning, in particular the mixing unit (106), the pumping unit (110), an application unit and / or auxiliary units, the

The cleaning system (114) preferably has a fluid pump (122) for removing a cleaning fluid and the cleaning system is preferably designed to be fed with treated water and / or to treat water.

5. Manufacturing system (1) according to one of the preceding claims, wherein the first manufacturing module (100) has a first metering unit and / or weighing unit which is or are set up to set a component-specific mixing ratio between the first material component and the second material component.

6. Manufacturing system (1) according to one of the preceding claims, wherein the second manufacturing module (200) has a second handling unit (222) for carrying out support processes, in particular for post-processing the composite material, for Insertion of reinforcement elements, for the insertion of component components and / or for the integration of components to secure the component transport.

7. Manufacturing system (1) according to one of the preceding claims, wherein the second manufacturing module (200) comprises a turntable (232) for rotating the component, and / or a first tool changing system (214) for exchanging from the first handling unit (212) and / or the second handling unit (222) used tools.

8. Manufacturing system (1) according to one of the preceding claims, wherein the first handling unit (212) and / or the second handling unit (222) is or are arranged in a flexible manner, wherein preferably the first handling unit (212) and / or the second handling unit ( 222) is or are arranged on a linear axis (224).

9. Manufacturing system (1) according to one of the preceding claims, wherein the second manufacturing module (200) has at least two, preferably three, separate sub-modules, a first sub-module (210) the first handling unit (212) and / or - a second sub-module ( 220) the second handling unit (222) and / or a third sub-module (230) has the turntable (232), at least two of the sub-modules being designed to be transportable separately from one another.

10. Manufacturing system (1) according to one of the preceding claims, comprising a third manufacturing module (300) with a loading unit (302) for the provision of material components, in particular additives, in particular powdery, fibrous and / or liquid additives, and / or additives and / or binders, the charging unit (302) preferably comprising a feed device and a conveying unit and / or a metering unit.

11. Manufacturing system (1) according to one of the preceding claims, wherein the third manufacturing module (300) comprises a second weighing unit, which is set up to weigh and / or dose binding agent, and / or comprises a further weighing unit, to add additives and / or to weigh and / or meter additives, and / or comprise further metering units (304) which are set up to meter additives and / or additives, and / or a coolant system for cooling the composite material, in particular a flake ice system for production and / or or providing ice to cool the composite material.

12. Manufacturing system (1) according to one of the preceding claims, wherein the first manufacturing module (100), the second manufacturing module (200), the third manufacturing module (300) and / or one, several or all of the sub-modules (210, 220, 230) have a housing and / or is or are designed as a transport unit, with side walls of the housing preferably being at least partially openable, in particular an upper housing part being designed to be extendable and / or liftable, and / or

Have side walls, floors and / or ceilings that have heat-insulating and / or sound-insulating material.

13. Manufacturing system (1) according to one of the preceding claims, wherein the first manufacturing module (100), the second manufacturing module (200), the third manufacturing module (300) and / or one, several or all of the sub-modules (210, 220, 230) have a first floor and a vertically spaced second floor Forming an intermediate space between the first floor and the second floor, wherein a drainage channel for the disposal of cleaning fluid is preferably set up in the intermediate space.

14. A method for the generative production of a component, preferably a concrete component, in particular using a spraying method, preferably a shotcrete method, comprising the steps:

Providing (500) a first material component, preferably a first concrete component, and a second

Material component, preferably a second concrete component, in particular on a supply unit (102, 104) of a manufacturing system (1),

Generating (502) a composite material, preferably a concrete, by mixing the first material component, preferably the first concrete component, and the second material component, preferably the second concrete component, in particular in a mixing unit of the manufacturing system (1), and additive manufacturing (504) of the component with the composite material, preferably the concrete component with the concrete, preferably by means of a spraying process, further preferably by means of a sprayed concrete process, in particular with a first handling unit.

15. The method according to the preceding claim 14, comprising the step or steps:

Metering (506) the first material component, preferably the first concrete component, and the second material component, preferably the second concrete component, in a component-specific mixing ratio, and / or

Vibrating and / or pumping (508) the composite material, preferably the concrete, from the mixing unit to the first handling unit, and / or

Reworking the component, preferably the concrete component, inserting a reinforcement element and / or inserting (510) component components and / or integrating components for component transport.

16. A method for setting up a manufacturing system (1) for the generative production of components, preferably concrete components, in particular for carrying out a spraying process, preferably a shotcrete process, for the generative production of components, preferably concrete components, comprising the steps:

Providing (600) a first production module (100) with a mixing unit (106) for producing a composite material, in particular a concrete, based on material components, preferably concrete components, in particular by mixing a first material component, preferably a first concrete component, and a second material component , preferably a second concrete component,

Providing (602) a second production module (200) with a first handling unit (212) for the generative production of a component with the composite material, preferably a concrete component with the concrete, in particular for the production of a sprayed component, preferably a shotcrete component, and

Coupling (604) the first production module (100) and the second production module (200) in such a way that the composite material produced in the mixing unit, preferably that in the mixing unit (106) produced concrete, can be brought to the first handling unit (212).