Formwork-free continuous production of adaptive support structures from variable frame elements– Adaptive Concrete Diamond Construction (ACDC) and beyond

利用可变框架元件连续生产自适应支撑结构，无需模板，自适应混凝土钻石结构 (ACDC) 及其他

• 批准号: 424057211
• 负责人: Professor Dr.-Ing. Daniel Lordick
• 金额: --
• 依托单位: Institut für Baustoffe
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/424057211?language=en
• 关键词: Formwork; free; continuous; production; adaptive

Concrete shells are among the most effective surface-forming load-carrying structures. These material-minimized structures are becoming increasingly attractive in terms of improving environmental sustainability in construction. However, their wide use has been hindered by the standard cast-in-place technology, which to date requires extremely labor-intensive curved formwork and elaborate casting. To resolve this problem, a technology for the automated flow production of flat modules for the subsequent assembly of concrete gridshells was successfully developed in the first phase of the ACDC project and validated through the fabrication of a demonstrator. The project delivered numerous scientific findings in the fields of computer-based design of gridshells and digital fabrication with cement-based materials.In the second phase the project aims to go beyond planar modules; this is also reflected in its new title: ACDC and beyond. The use of double-curved modules and spatial trusses will significantly expand the available geometries for modular shells and push geometric optimization options to a new level. Upcoming research tasks include the parametric modeling of shell structures, the development of algorithms for their segmentation, and their geometric optimization based on the structural analysis performed. Another objective is the development of detachable module connections, which will enable rapid assembly and disassembly of modular structures as well as repair and reuse of individual modules.The transition from planar to double-curved modules leads to considerable technological challenges. For fabrication, an adaptive platform for placing concrete will be built, which is capable of automatically deforming into the required surface geometry. The modules consist of an edge zone and an infill. The edge zone is created by 3D printing using a newly developed strain-hardening cement based composite (SHCC) based on a sustainable binder limestone calcined clay cement (LC3). SHCC ensures high strength and high ductility of the modules for their interaction within the structure as well as high robustness during their transportation and assembly. The curved shapes pose high demands on steering the rheology of the fresh infill concrete and on its time-dependent properties. The infill is reinforced by a freeform robotic textile yarn-laying system based on the requirements resulting from the structural analysis.To establish a direct link between design and manufacturing, an automated data flow system will be created to enable the steering of the adaptive platform, the 3D printer, and the robotic arms based on the specified module geometry. The module fabrication line will be equipped with an in-line control system that will allow the automatic detection of inconsistencies and make the necessary adjustments to the production process. In return, design and layout of the modules will be informed by the production parameters in an iterative process.

混凝土壳体是最有效的表面成型承重结构之一。这些材料最少的结构在改善建筑环境可持续性方面正变得越来越有吸引力。然而，标准的现浇技术阻碍了它们的广泛使用，到目前为止，这种技术需要极其劳动密集型的曲面模板和精细的铸造。为了解决这一问题，在ACDC项目的第一阶段，成功地开发了用于随后组装混凝土网壳的平板模块的自动化流水作业技术，并通过制造演示器进行了验证。该项目在网壳的计算机设计和水泥基材料的数字制造领域取得了许多科学成果。在第二阶段，该项目的目标是超越平面模块；这也反映在它的新标题：ACDC和Beyond。双曲模块和空间桁架的使用将极大地扩展模块化壳体的可用几何形状，并将几何优化选项推向一个新的水平。未来的研究任务包括壳结构的参数化建模、壳结构分割算法的开发以及基于结构分析的几何优化。另一个目标是开发可拆卸的模块连接，这将使模块结构的快速组装和拆卸以及单个模块的修复和重复使用成为可能。从平面模块到双曲线模块的过渡带来了相当大的技术挑战。对于制造，将建立一个自适应的混凝土浇注平台，能够自动变形为所需的表面几何形状。这些模块由边缘区域和内嵌组成。边缘区域是通过3D打印创建的，使用一种新开发的应变硬化水泥基复合材料(SHCC)，该复合材料基于可持续粘结剂石灰石煅烧粘土水泥(LC3)。SCC确保了模块在结构内相互作用时的高强度和高延展性，以及在运输和组装过程中的高健壮性。曲线形状对控制新浇注混凝土的流变性及其时变特性提出了很高的要求。根据结构分析产生的要求，通过自由形式的机器人纺织铺纱系统对填充物进行加固。为了在设计和制造之间建立直接联系，将创建一个自动数据流系统，以使自适应平台、3D打印机和机械臂能够基于指定的模块几何形状进行转向。模块生产线将配备在线控制系统，允许自动检测不一致并对生产过程进行必要的调整。作为回报，模块的设计和布局将通过迭代过程中的生产参数进行通知。