초록 ▼

A robotic casting machine (RCM) provides for on-site, or near-site casting and automated production of cast components, such as concrete modular, volumetric building components. The RCM includes stationary and mobile support structures, which can be positioned in a loading configuration, a casting c

A robotic casting machine (RCM) provides for on-site, or near-site casting and automated production of cast components, such as concrete modular, volumetric building components. The RCM includes stationary and mobile support structures, which can be positioned in a loading configuration, a casting configuration and an ejection configuration in which the cast volumetric component may be ejected from the mold. Tipping machines located beneath the cast component facilitate ejection, rotation and loading of the ejected module onto a transport surface for transport of the module. The support structures are constructed of prefabricated frames that may include at least one standardized section, which may be utilized on every project, and may also include a customized section, which may be provided to achieve desired dimensions of the cast module on a particular project. A casting process is provided in which a volumetric module is cast in a rotated orientation, in which the floor is cast with an initial vertical orientation, the transverse walls extend in a horizontal orientation, which is cast in vertical wall forms, and a longitudinal wall extends horizontally along the top of the mold. Modular, volumetric components created using the RCM and casting process are also described.

대표청구항 ▼

1. Methods of constructing a building from volumetric modular building components cast with a portable robotic casting machine (RCM), the method comprising: a. assembling an RCM at a casting site;b. casting a first volumetric modular building component using the RCM, the first volumetric modular bui

1. Methods of constructing a building from volumetric modular building components cast with a portable robotic casting machine (RCM), the method comprising: a. assembling an RCM at a casting site;b. casting a first volumetric modular building component using the RCM, the first volumetric modular building component having at least two transverse walls, a longitudinal wall extending between the transverse walls, and a floor adjoining the transverse and longitudinal walls;c. assembling the first volumetric modular building component in a building structure;d. casting a second volumetric modular building component using the RCM, the second volumetric modular building component having at least two transverse walls, a longitudinal wall extending between the transverse walls, and a floor adjoining the transverse and longitudinal walls;e. assembling the second volumetric modular building component in the building structure either adjacent to or spaced a predetermined distance from the first volumetric modular building component;f. casting at least one infill building component having at least a floor and placing it in the building;g. assembling the second volumetric modular building component either adjacent to or between infill building components;h. casting an extender building component using the RCM, the extender building component having at least two transverse walls, and a floor adjoining the transverse and longitudinal walls;i. assembling the extender building component adjacent to and attached to the floor and transverse walls of at least one of the first and second volumetric building component such that the extender building component, infill building component and first and second volumetric building components define a living unit. 2. The method of claim 1, further comprising the step of casting the first and second volumetric building components, and the extender building component in a rotated position relative to the position in which the components are oriented when installed in the building structure. 3. The method of claim 1, further comprising lifting and rotating the first and second volumetric building components and the extender building component onto a transport after casting for transport to the building structure. 4. The method of claim 1, wherein the step of assembling the RCM comprises assembling the RCM from modular components shipped to the casting site. 5. The method of claim 1, wherein the step of casting the volumetric building components and extender building component is automated. 6. The method of claim 1, wherein the step of assembling the RCM comprises assembling mobile and stationary structural components and molding surfaces which cooperate to configure the apparatus to: a. a closed casting configuration in which the volumetric modular building components are cast; b. an ejection configuration, in which the volumetric modular building components are ejected from the mold and rotated onto a transport device for transport; c. an open reloading position, in which the molding surfaces are accessed for preparation for casting of a subsequent volumetric modular building component. 7. The method of claim 1 wherein the step of assembling the RCM comprises assembling at least one lifting mechanism for lifting and rotating the molded volumetric modular building components onto a transport after casting. 8. The method of claim 1, wherein the steps of casting the first and second volumetric modular building component comprise casting the floor in a vertical orientation, and the longitudinal wall in a horizontal orientation above the transverse walls. 9. The method of claim 1, further comprising the step of disassembling the RCM and storing the RCM compactly in shipping containers. 10. The method of claim 1, wherein the step of assembling the RCM comprises assembling actuators and an electronic control system for controlling the actuators to automate movement of mobile components of the RCM relative to stationary components of the RCM. 11. The method of claim 1, wherein the step of assembling the RCM comprises assembling at least one lifting mechanism having a tipping arm pivotably connected to a base member. 12. The method of claim 1, wherein the step of assembling further comprises assembling a tensioning system to maintain the volumetric modular building components supported against a tipping arm as pivoting proceeds. 13. The method of claim 1, further comprising providing an actuator for rotating a tipping arm until the volumetric modular building component reaches a balancing point. 14. The method of claim 13, comprising providing a second actuator for allowing the volumetric modular building component to slide downward after the balancing point is reached.