Method and Device for Building Automatically Conglomerate Structures

Abstract

The present invention relates to the automatic construction of buildings or other heavy constructions by a method and a device suitable for reducing the construction time and for assisting its relative operations. This method comprises the steps of CAD-modelling a structure through volume or surface modelling steps, sectioning the structure computed model with horizontal parallel planes according to a predetermined pitch, prearranging an apparatus that deposits in alternation a layer of granular material and a liquid binder only in coincidence with the solid portions of said plane, within containing walls that define a closed perimeter. This method can be carried out by an apparatus having a horizontal frame ( 1 ) suitable for supporting a bridge crane ( 15 ) capable of causing and operating head to move ( 16 ) in a horizontal plane defined by said horizontal frame ( 1 ). The frame ( 1 ) is movable along four uprights ( 3, 4, 5, 6 ) vertically ( 11,12,13,14 ), the bridge crane ( 15 ) is sliding horizontally ( 18 ), and the operating head is sliding horizontally ( 19 ).

1 . A method for building automatically conglomerate structures, characterized in that it comprises the steps of:
 CAD modelling a structure of building, in particular with a CAD function of surface modelling or of volume modelling, obtaining a computer file structure model;   sectioning said computer file structure model with horizontal parallel planes, in particular planes that are equidistant according to a predetermined pitch, in order to generate a plurality of cross section planes of the structure comprising solid and empty areas, corresponding to the solid and empty parts of the structure, said planes being sorted from below towards the above;   prearranging, within containing walls that define a closed perimeter, an apparatus suitable for depositing in alternation a layer of granular material and a liquid binder.   moving said apparatus within said perimeter in order to deposit a first uniform horizontal layer of granular inert material of thickness corresponding to said predetermined pitch;   spraying a first layer of binder by said apparatus in order to reproduce a first plane of said cross section planes, forming a layer of inert material and of binder only at said solid areas, said apparatus having an operating head suitable for moving in a horizontal plane;   raising vertically said apparatus according to said pitch;   repeating the deposition step of granular inert material and repeating on it the binder spraying step as many times as are the horizontal cross sections of the structure, each time for a different and vertically next cross section plane, up to complete the last layer;   removing the inert material that has not been bond by the binder and that has accumulated within said perimeter, freeing a solid structure that repeats accurately said structure model.   
   
   
       2 . Method according to  claim 1 , wherein said step of modelling provides a step of enveloping said structure or a portion of it with a plurality of elementary volumes, and, in particular said single volumes are selected from the group comprised of: parallelepipeds, cylinders, prisms, spheres or parts or combinations of them. 
   
   
       3 . Method according to  claim 1 , wherein said single volumes have vertical edges or vertical generatrix parallel to vertical sides of said structure and have horizontal edges parallel to the horizontal planes of said structure. 
   
   
       4 . Method according to  claim 1 , wherein said apparatus comprises an operating head piloted on said horizontal plane with independent motion or interpolated motion according to Cartesian or polar coordinates. 
   
   
       5 . Method according to  claim 1 , wherein said resin is selected from the group comprised of:
 epoxy resins;   cross linking polyurethane.   
   
   
       6 . Method according to  claim 1 , wherein said resin has a viscosity set between 3 and 10 poises, and preferably between 6 and 8 poises, and is adapted to be fluid enough to penetrate between the granules of the granular material for a height corresponding to said pitch thus achieving the layer of granular material previously formed. 
   
   
       7 . Method according to  claim 1 , wherein said granular material has a granulometry of value set between 0.1 and 2 mm, and preferably between 0.5 and 1.5 mm whereby it has a value of maximum effective porosity adapted to cause said binder to penetrate between the deposited granules up to reaching the layer already sprayed in the previous cycle. 
   
   
       8 . An apparatus for building automatically conglomerate structures, characterized in that it comprises:
 a closed perimeter defined by containing walls;   a horizontal frame suitable for supporting a bridge crane capable of causing an operating head to move in a horizontal plane defined by said horizontal frame within said perimeter;   means for actuating said operating head on said horizontal plane parallel to said bridge crane;   a framework having at least one upright capable of supporting said horizontal frame;   means for moving said horizontal frame in a vertical direction;   a control unit suitable for controlling the succession of operations up to completion of said structure;   wherein said containing walls are capable to contain said inert material in a working area larger than said conglomerate structure.   
   
   
       9 . Apparatus according to  claim 8 , wherein said operating head comprises a blade that is adapted to slide on the deposited inert material to uniform it in order to achieve a predetermined thickness, on the whole working area. 
   
   
       10 . Apparatus according to  claim 8 , wherein said containing walls are vertical and define a parallelepiped or cylindrical volume on said working area. 
   
   
       11 . Apparatus according to  claim 8 , where a covering is provided for roofing said containing walls. 
   
   
       12 . Apparatus according to  claim 11 , wherein said covering is capable of stopping hermetically said volume so that a vacuum can be created inside. 
   
   
       13 . Apparatus according to  claim 8 , wherein said operating head comprises:
 at least one binder spraying nozzle operated by a controlled electro valve;   a premixing head;   a feeding pump;   a reservoir;   a washing system.   
   
   
       14 . Apparatus according to  claim 8 , wherein said operating head comprises a volumetric doser for supplying said operating head with a known amount of inert material for each stroke.