Patent Description:
The 3D printing technology has the advantages of fast forming speed, lower expense, smaller occupied production space, etc., in the production of structurally complex material members such as concrete, and thus already has exploratory applications in the field of construction, bridges and the like. In general, existing printing is used for model construction in such a way that printing is performed on flat ground or structural members are printed in a factory in advance and then are assembled on site, while there are still application blanks in environments with poor environment adaptability, complex terrains and narrow regions. Today, ramp protection projects (grid beams) are mostly performed manually, and employs a manner of conventional erecting formwork and cast-in-place concrete, resulting in slow construction progress, high resource demands, and lower safety. In fact, prior to the on-site construction process, the bottom of a to-be-printed building is generally not horizontally disposed, resulting in that a 3D printing device cannot print non-horizontal planes such as ramp protection.

The <CIT> discloses a robotic system having a movable gantry robot for conducting construction operations. The gantry may have an expandable bridge and articulated gantry support legs as well as a support track system holding a gantry robot which may hold one or more implements and peripheral devices. The device can be moved by propulsion mechanisms, a controller, and one or more geo-positioned control devices to provide position information for the robotic gantry as it moves back and forth along a plurality of work sites. The robotic gantry is connected to a power supply system. The controller is automated, self-navigating, and activates, deactivates, and/or changes the operation of the propulsion mechanisms, and deploys, retracts, activates, deactivates, and/or changes the operation of one or more of the construction implements.

Accordingly, the technical problem to be solved by the present invention is to overcome the defects that 3D printing devices in the prior art cannot print non-horizontal-plane, non-prefabricated foundation ground such as ramp protection, thereby providing a multi-functional concrete 3D printing device.

In order to solve the above problem, the present invention provides, according to claim <NUM>, a multi-functional concrete 3D printing device.

Optionally, the angle adjusting member is a spherical plain bearing.

Optionally, a side wall of the nozzle is fixedly provided with an altimeter that is in communication connection with the controller.

Optionally, the print carriage includes at least two transverse beams and two longitudinal beams, and is provided with a camera and the nozzle. The transverse beams and the longitudinal beams enclose a truss. Transverse power members are disposed on the transverse beams, and longitudinal power members are disposed on the longitudinal beams. The camera is disposed towards a spraying direction of the nozzle, and the controller is in communication connection with the camera. Caterpillar bands or slide rails are paved on the transverse beams and the longitudinal beams. The transverse power members and the longitudinal power members are respectively in communication connection with the controller.

Optionally, the multi-functional concrete 3D printing device further includes a feeding structure that includes a concrete tank, a delivery pump and a feeding tube. The concrete tank and the delivery pump are disposed on a side surface of the control chamber. The feeding tube is disposed at an output end of the delivery pump, goes by the control chamber and the arm lever in sequence and then is connected to the nozzle. The delivery pump is in communication connection with the controller.

Optionally, the multi-functional concrete 3D printing device further includes a power structure disposed at an end of the control chamber facing away from the arm lever, and a walking structure disposed below the control chamber. The power structure includes an actuator and a counterweight case. The walking structure is rotationally connected to the control chamber.

Optionally, the multi-functional concrete 3D printing device further includes a nozzle yaw power shaft that is driven by the nozzle yaw power member to rotate in a yaw fixed shaft sleeve. The nozzle yaw power shaft is fixedly connected to a yaw movable sleeve, and the yaw movable sleeve is fixedly connected to a nozzle support and the nozzle below the nozzle support. The nozzle yaw power shaft drives the nozzle support and the nozzle to swing when in rotation. The angle rotating member is fixed onto a nozzle base by a nozzle base support. The nozzle base drives the nozzle to slide linearly on the transverse beams. The angle rotating member drives a rotating shaft support and the nozzle below the rotating shaft support to rotate while driving a rotating shaft to rotate, thereby implementing movement of the nozzle in respective dimensions.

A use method of a multi-functional concrete 3D printing device, according to an embodiment not covered by the present invention, is implemented as follows. A controller controls individual legs to extend, and the individual legs are extended by set lengths calculated by the controller upon contact with a bottom surface of a to-be-printed concrete model. An angle adjusting member drives a print carriage to rotate, such that the print carriage maintains a printing angle with the ground of the to-be-printed concrete model. Subsequently, the controller controls a nozzle yaw power member and an angle rotating member to rotate, and adjusts the angle of a nozzle, thereby forming a desired concrete printing angle through joint control.

Optionally, the use method includes the following steps:.

In order to illustrate more clearly the specific embodiments of the present invention or the technical solutions in the prior art, the drawings required for description of the specific embodiments or the prior art will be briefly described below. It will be apparent that the drawings in the following description are some embodiments of the present invention, and a person of ordinary skill in the art can obtain other drawings based on these drawings without inventive step.

Reference numerals: <NUM>. caterpillar band; <NUM>. walking structure; <NUM>. control chamber; <NUM>. delivery pump; <NUM>. concrete tank; <NUM>. actuator; <NUM>. counterweight case; <NUM>. arm lever; <NUM>. planetary gear; <NUM>. slewing gear; <NUM>. longitudinal beam; <NUM>. leg; <NUM>. transverse power member; <NUM>. connecting line; <NUM>. transverse beam; <NUM>. nozzle; <NUM>. reinforcing rib; <NUM>. camera; <NUM>. feeding tube; <NUM>. spray power member; <NUM>. material inlet; <NUM>. altimeter; <NUM>. rotating shaft support; <NUM>. nozzle base support; <NUM>. nozzle base; <NUM>. angle rotating member; <NUM>. rotating shaft; <NUM>. yaw fixed sleeve; <NUM>. yaw movable sleeve; <NUM>. nozzle support; <NUM>. nozzle yaw power member; <NUM>. nozzle yaw power shaft.

The technical solutions of the present invention will now be clearly and fully described in conjunction with the drawings, and it will be apparent that the described embodiments are some, but not all, embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments according to the claims are within the scope of protection of the present invention.

In the description of the present invention, it should be noted that, the orientation or position relation indicated by terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like is based on the orientation or position relation shown in the drawings. The terms are only for describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation and be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. Moreover, the terms "first", "second", "third" are used for descriptive purposes only and cannot be construed to indicate or imply relative importance.

Throughout the description of the present invention, it is to be noted that, unless expressly specified and defined otherwise, the terms "mount", "link" and "connect" should be broadly understood, For example, it can be fixed connection, detachable connection or integrated connection; it can be mechanical connection or electrical connection; and it can be direct connection or indirect connection through intermediate media, and may be internal connection of two elements. A person of ordinary skill in the art may understand the specific meaning of the above terms in the present invention according to specific situations.

Furthermore, technical features involved in different embodiments of the present invention described below can be combined with each other, according to the claims.

The present invention provides a multi-functional concrete 3D printing device, including: a control structure, including a control chamber <NUM> and arm levers <NUM> which are in transmission connection; a printing structure, being disposed at an end of the arm lever <NUM> away from the control chamber <NUM>, being connected to the arm lever <NUM>, and including a print carriage, a nozzle <NUM> disposed on the print carriage, and at least one adjustable leg <NUM> disposed on the print carriage, wherein an angle adjusting member is disposed between the print carriage and the arm lever <NUM>, the nozzle <NUM> is provided with a nozzle yaw power member <NUM> and an angle rotating member <NUM>, the controller controls the extension length of the leg <NUM> to cause the angle adjusting member to drive the print carriage to rotate, and the nozzle <NUM> sprays from different angles by rotation of the print carriage, and rotation of the nozzle yaw power member <NUM> and the angle rotating member <NUM>. When in a printing state, the controller controls the extension length of the legs <NUM> to maintain a spatial height with the ground required for printing, and then the print carriage is adjusted by the angle adjusting member for rotation, such that the nozzle <NUM> is driven to rotate by the rotation of the print carriage. Meanwhile, the controller controls the nozzle yaw power member <NUM> and the angle rotating member <NUM> to rotate, and the nozzle <NUM> adapts to different plane angles during construction on site so as to perform non-horizontal plane printing under the joint action of an print carriage, the nozzle yaw power member <NUM> and the angle rotating member <NUM>.

A specific embodiment of a 3D printing device as shown in <FIG> includes a control structure including a control chamber <NUM> and an arm lever <NUM>, a printing structure disposed on an end of the arm lever <NUM> away from the control chamber <NUM>, a walking structure <NUM> disposed below the control chamber <NUM>, and a power structure disposed at an end of the control chamber <NUM> facing away from the arm lever <NUM>. The arm lever <NUM> is provided as a multi-section boom. The relative rotation between the multiple sections of the boom is ensured by means of pins and bearings, and the relative rotation between the adjacent sections of the boom is achieved by oil cylinders or steel wire ropes.

As shown in <FIG>, the printing structure includes a print carriage, and a nozzle <NUM> disposed on the print carriage. For angular rotation of the print carriage, an angle adjusting member is disposed on the print carriage. Specifically, the angle adjusting member is a spherical plain bearing. To drive the print carriage to rotate, a slewing structure is disposed between the print carriage and the arm lever <NUM>, and includes a planetary gear <NUM> disposed on the arm lever <NUM>, a slewing gear <NUM> disposed on the print carriage, and a slewing power member for driving the planetary gear to rotate, wherein the planetary gear <NUM> is meshed with the slewing gear <NUM>. Specifically, the slewing power member is preferably a servo motor or other appropriate types of motors. As shown in <FIG>, the print carriage includes at least two transverse beams <NUM> and two longitudinal beams <NUM>. The transverse beams <NUM> and the longitudinal beams <NUM> enclose a truss. Transverse power members <NUM> are disposed on the transverse beams <NUM>, and longitudinal power members are disposed on the longitudinal beams <NUM>. The transverse power members <NUM> drive the nozzle <NUM> to move transversely, and the longitudinal power members drive the transverse beams <NUM> to move longitudinally.

Specifically, the transverse power members <NUM> and the longitudinal power members are preferably servo motors or other appropriate types of motors. To reinforce the connection between the transverse beams <NUM> and the arm lever <NUM>, a reinforcing rib <NUM> is disposed at the connection position of the transverse beams <NUM> and the arm lever <NUM>. To facilitate support and adjustment of the angle of the print carriage, two ends of each longitudinal beam <NUM> are respectively provided with at least one adjustable leg <NUM> that is used to adjust the relative height and angle of the print carriage to the ground, such that the print carriage can adapt to to-be-printed concrete models in different shapes and at different angles, to meet different construction needs. Specifically, the leg <NUM> is a hydraulically stretchable leg. Meanwhile, the leg <NUM> may also provide good support for the print carriage, which avoids impacting printing quality during printing due to feeding or vibration, and ensures that the print carriage is parallel to or forms a preset angle with the surface of to-be-printed concrete, thereby printing planar or curved concrete, and ensuring printing quality. To capture printed images in real time, an end of the arm lever <NUM> close to the print carriage is provided with a camera <NUM> that is disposed towards a spraying direction of the nozzle <NUM>. To measure the height of the print carriage, a plurality of altimeters <NUM> are also disposed on a circumferential side wall of the nozzle <NUM>. The respective altimeters <NUM> measure the heights of the ground and the heights of printed concrete in different directions, and data is fed back to the control chamber <NUM> for comparison to confirm actual heights of individual points that need to be printed on the uneven ground and whether the height of the printed concrete meets the design requirements.

To control the flow rate sprayed by the nozzle <NUM>, a spray power member <NUM> is disposed at the nozzle <NUM>. Specifically, the spray power member <NUM> is preferably a servo motor or other appropriate types of motors. To measure the angle between the print carriage and a horizontal plane, the 3D printing device further includes an angle meter.

To facilitate rotation of the nozzle <NUM>, the nozzle yaw power member <NUM> drives a nozzle yaw power shaft <NUM> to rotate in a yaw fixed shaft sleeve <NUM>, and the nozzle yaw power shaft <NUM> is fixedly connected to a yaw movable sleeve <NUM> that is fixedly connected to a nozzle support <NUM> and the nozzle and associated mechanisms below the nozzle support <NUM>. The nozzle yaw power shaft <NUM> drives the nozzle support <NUM> and the nozzle <NUM> to swing when in rotation. The angle rotating member <NUM> is fixed onto a nozzle base <NUM> by a nozzle base support <NUM>. The nozzle base <NUM> drives the nozzle and associated mechanisms to slide linearly on the transverse beams <NUM> and rails. The angle rotating member <NUM> drives a rotating shaft support <NUM> and the nozzle <NUM> below the rotating shaft support <NUM> to rotate while driving a rotating shaft <NUM> to rotate, thereby implementing movement of the nozzle in respective dimensions.

To facilitate control, a controller is disposed in the control chamber <NUM>, wherein the controller is in communication connection with the slewing power member, the transverse power members <NUM>, the longitudinal power members, the spray power member <NUM>, the nozzle yaw power member <NUM>, the angle rotating member <NUM>, the camera <NUM>, the altimeters <NUM>, the angle meter, the nozzle <NUM> and the legs <NUM>, respectively. It should be noted that connecting lines <NUM> pass through holes in the angle adjusting member to be connected to structures of various parts of the print carriage. To print different trajectories, patterns of grid beams, ramp angles, cross sections of grid beams or the like are set in a preset program in the controller, and three-dimensional simulated grid beams are preset in the controller. Parameters such as coordinates of a to-be-printed ramp region, an inclination angle, etc., are input into the controller before printing, and the pattern of a to-be-printed grid beam is selected in the control program. If there is no pattern of the to-be-printed grid beam in a pattern library, a new pattern of the grid beam is formed by setting specific parameters.

To power the control chamber <NUM>, the 3D printing device further includes a power structure that is disposed at an end of the control chamber <NUM> away from the arm lever <NUM>. The power structure includes an actuator <NUM> and a counterweight case <NUM>, wherein the actuator <NUM> is in communication connection with the controller to achieve multi-structure ganged control by the controller. It should be noted that modifications can be made on the basis of existing mature construction equipment platforms, such that the power structure provides power for the entire device.

To provide concrete, the 3D printing device further includes a feeding structure that includes a concrete tank <NUM>, a delivery pump <NUM> and a feeding tube <NUM>. The concrete tank <NUM> and the delivery pump <NUM> are disposed on the side surface of the control chamber <NUM>. The feeding tube <NUM> is disposed at an output end of the delivery pump <NUM>, goes by the arm lever <NUM> and then is in pipeline connection with a material inlet <NUM> the nozzle <NUM>. The delivery pump <NUM> is in communication connection with the controller. Specifically, the delivery pump <NUM> is a screw pump.

In particular use, on-site personnel operates the controller in the control chamber <NUM> to control caterpillar bands <NUM> of the walking structure <NUM> to a to-be-printed position, and to control an arm head to extend to the to-be-printed ground which is divided into a plurality of to-be-printed regions. Meanwhile, a long-side printing manner, a short-side printing manner or an oblique printing manner is selected by rotating the print carriage by the slewing power member according to a size and a length-width ratio of the to-be-printed region, thereby adapting to ramps in various angles and ramp concrete in various patterns and shapes. An initial print sideline is preset in the controller, one side of the print carriage is selected to be aligned with the initial print sideline, and a program can automatically control the print carriage to move to be aligned with the initial print sideline. The on-site personnel observes video signals captured by the camera <NUM> and stops the rotation of the print carriage after the edge of the print carriage is aligned with the line of the to-be-printed region, and the controller plans printing lines.

After confirming that the print carriage is aligned with the to-be-printed region, the legs <NUM> at four corners of the print carriage extend out. In the case that it is ensured that the print carriage remains parallel to the ground or forms a preset angle with the ground, the control system controls the legs <NUM> at four corners to extend by respective calculated lengths by measurement made by the altimeters <NUM> disposed on the print carriage, so as to adjust the print carriage to be parallel to or to form the preset angle with the ground where concrete is to be printed, thereby printing planar or curved concrete. When an oil cylinder of each leg <NUM> is stressed when in contact with the ground, the spherical plain bearing at the connection position of the arm lever <NUM> and the print carriage performs rotation and adaptive adjustment under the retroaction of the supporting force of oil cylinders of the legs <NUM> to the ground, thereby achieving the adaptive leveling of the angle of the print carriage. Such a structure design is simple, efficient and practical, without the need of design and installation of a multi-dimensional adjustment mechanism at the spherical plain bearing. A plurality of altimeters <NUM> prearranged on the print carriage are used to make an overall height measurement of the ground within the region of the print carriage at this time. Data is transmitted to the control system for comparison to confirm actual heights of individual points that need to be printed on the uneven ground. A concrete discharging rate and an operating speed of the nozzle <NUM> at the individual points on the print path systematically and accurately in conjunction with the above settings in the control program such that if an original ground is lower than that as planned by an original system, the nozzle <NUM> can print more concrete at this point by accelerating the concrete discharging rate and decreasing the movement speed of the nozzle <NUM> to achieve the originally designed concrete print height, and vice versa. The compassion is performed with the height of concrete that needs to be printed at this point and is preset by the system after detection, and then whether the height of the printed concrete meets design requirements is determined and corrected. It is thereby ensured that the printed concrete surfaces are at the same height in the case of printing of the uneven ground, or curved concrete with unequal heights is printed according to the preset requirements.

After preparation, the controller starts the delivery pump <NUM>, and drives the transverse beam <NUM> power members and the longitudinal beam <NUM> power members to move to drive the nozzle <NUM> to spray concrete slurry according to a previously planned path for printing. Meanwhile, the altimeters <NUM> perform height measurement, and the measured data is transmitted to the controller for comparison to confirm the concave-convex shape of the surfaces at different positions on the ground. The print carriage remains parallel to or forms a preset angle with the surface of the to-be-printed concrete, thereby controlling the nozzle <NUM> to spray concrete slurry with different flow rates, and controlling the legs <NUM> to be slightly stretch to ensure an optimal spraying angle of the nozzle <NUM>.

When the to-be-printed region is printed, the next to-be-printed region continues, the print carriage repeats the above cycle after being aligned with the alignment line preset in the system or aligned with an edge of a last concrete module printed, and reciprocates until the entire printing operation of the to-be-printed ground is finished. It should be noted that the three-dimensional simulated grid preset in the controller is automatically fitted with the grid beam captured by the camera to perform prompt when differences occur, and correction, making up and improvement are performed for subsequent printing.

A control system includes a device movement platform control system, a feeding control system, a printing control system, and the like. The control system can perform on-site control, or perform remote control. The control system performs organizational control on the device movement platform control system, the feeding control system and the printing control system through advanced design, built-in software and hardware planning.

Notably, when a curved or ramp concrete model needs to be printed, an angle value of the print carriage measured by the angle meter is transferred to the controller during printing, the individual legs <NUM> of the print carriage are adjusted to extend by unequal lengths based on the values calculated by the controller, and stretch by different lengths rapidly at the individual points based on the pre-planned path on the premise of continuous printing, such that an angle is formed between the print carriage and the to-be-printed printed ground, and thus an unequal-height space is reserved for the printed concrete, thereby facilitating the printing of the curved or ramp concrete. The legs <NUM> may provide reliable support of the print carriage, which prevents the printing quality from being affected by the vibrations caused by feeding and printing in the printing process, thereby ensuring the printing quality. When the individual legs <NUM> are stressed when in contact with the ground, the angle adjusting member at the connection position of the arm lever and the print carriage performs rotation and adaptive adjustment under the retroaction of the supporting force of the legs <NUM> to the ground, thereby achieving the adaptive leveling of the angle of the print carriage. In the whole process, the angle adjusting member has the advantages of simplicity, efficiency and practicability, without the need of design and installation of a multi-dimensional adjustment mechanism. When printing is finished, a printing arm of the printing device is retracted and folded, and is retracted to the rear part of the device to facilitate transport. When the print carriage is large, a plurality of towing wheels may be disposed at a tail part to facilitate contact of the towing wheels with the ground after folding, to collectively perform long-distance transportation of the device as the platform walks. By way of the specific implementation described above, the printing device can print grid beams in varying shapes, for example, regular grid beams having a uniform cross section shape or non-regular grid beams all can be printed well.

The multi-functional concrete 3D printing device provided by the present invention has the following advantages: (<NUM>) With the parallelism measurement and adjustment system, the problem of low 3D printing accuracy is solved by the connection of the legs <NUM>, the altimeters <NUM> and the controller, and high-accuracy printing is achieved, so that the quality of the concrete print is guaranteed. (<NUM>) The degree of automation is high. With the collaborative work of the individual structures from 3D printed concrete production to precise positioning of the print, the controller plans the print path of the model in advance to perform dynamic adjustment in printing different concrete structures so as to achieve automation, and also controls the spraying amount of concrete slurry from the nozzle <NUM> based on the heights measured the altimeters <NUM>. (<NUM>) The versatility is strong. The 3D printing device is applicable to printing of concrete models in different shapes. An operator only need to monitor printing data in real time after the 3D printing device is started, ensuring the health of the operator. (<NUM>) The overall structure is compact and simple. The 3D printing device can adapt to different work platforms and sites, read relevant printing data in real time, is located at relevant positions, and has abundant structures and functions. (<NUM>) The working efficiency is high: the cooperative work of the print carriage and the controller is achieved to improve the working quality; and the print carriage freely moves in the printing region, so that the working efficiency is obviously improved. (<NUM>) A positioner reads the relevant data of the printing region in real time to ensure the printing effect.

As an alternative embodiment, the angle adjusting member may also be a round ball.

As an alternative embodiment, the delivery pump <NUM> may also be a gear pump or other types of pumps.

As an alternative embodiment, the legs <NUM> are in other stretchable forms, such as barometric stretchable legs, and the legs <NUM> may also be manually adjusted.

As an alternative embodiment, the print carriage may also be subjected to manual printing under the control of the operator.

As an alternative embodiment, four sides of the print carriage may also be provided with a print alignment line, and the position the print alignment line is photographed by the camera, and is transferred to the controller. An observer observes or a display screen in the control chamber shows the positions of the print alignment line and a reference print boundary, and enables the print alignment line to be aligned with the reference print boundary, thereby ensuring the alignment and proper engagement between concrete printed each time.

To solve the problems faced by the application of 3D concrete printing technology described above in complex geographical conditions such as ramp protection, there is a need for a 3D concrete printing system with good economy, high applicability and high working efficiency. The 3D printing device is applicable to numerous banded concrete printing, such as concrete grid beams, concrete barriers, concrete enclosures, etc., in various types of engineering construction projects with complex terrain conditions, is an intelligent, automated, economical 3D printing system with high accuracy and environmental adaptability for the above printing. The applicability and practicability of the device are comprehensively improved to achieve the working efficiency of 3D concrete printing under complex geographical conditions by the connection of the boom structure and the nozzle with the slewing and bi-directional movement mechanisms with assistance of the height measurement and calibration device and the corresponding control system.

Claim 1:
A multi-functional concrete 3D printing device, comprising:
a control structure, comprising a control chamber (<NUM>) and arm levers (<NUM>), wherein relative rotation between the arm levers (<NUM>) is ensured by pins and bearings, relative movement between the arm levers (<NUM>) is achieved by oil cylinders or steel wire ropes, and a controller of the control chamber (<NUM>) is in transmission connection with the arm levers (<NUM>) to control the action of the arm levers (<NUM>); and
a printing structure, being disposed at an end of the arm levers (<NUM>) away from the control chamber (<NUM>), being connected to the arm lever (<NUM>) at the end of said arm levers (<NUM>), and comprising a print carriage, a nozzle (<NUM>) disposed on the print carriage, and at least one adjustable leg (<NUM>) disposed on the print carriage, wherein an angle adjusting member is disposed between the print carriage and the arm lever (<NUM>), the nozzle (<NUM>) is provided with an angle rotating member (<NUM>) and a nozzle yaw power member (<NUM>), the controller controls the extension length of the leg (<NUM>) to cause the angle adjusting member to drive the print carriage to rotate, and the nozzle (<NUM>) sprays from different angles by rotation of the print carriage, and rotation of the nozzle yaw power member (<NUM>) and the angle rotating member (<NUM>):
characterized in that, a slewing structure is disposed between the print carriage and the arm lever (<NUM>), and comprises a planetary gear (<NUM>) disposed on the arm lever (<NUM>) and a slewing gear (<NUM>) disposed on the print carriage, wherein the planetary gear (<NUM>) is meshed with the slewing gear (<NUM>), and the slewing structure is in communication connection with the controller.