Design analysis and development of a gantry robot for multi-layer 3-D concrete printing with simulation and experimental validation

Abstract

The present study investigates the design analysis and development of a framed gantry robot (FGR) for 3-D concrete printing. Finite element simulations are performed for design validation and parameter estimation to conduct detailed analysis of the concrete printer. The kinematic and dynamic models of FGR are used for workspace analysis, motion control study, and motor sizing for printer development. The motion trajectory of the printer nozzle tip is evaluated using MATLAB simulations. An integrated programmable logic controller (PLC) with an in-built human-machine interface (HMI) through control algorithms has been implemented for interactive, user-friendly, and precise motion control. A separate control system is developed to monitor the pumping power and feed rate of mortar mix during printing. The simulated control scheme is validated experimentally using trajectory tracking for various input printing paths through HMI, with a maximum tracking error of 1 mm. Successful concrete printing trials have been conducted using various mix-design, following extensive evaluation of different printer and material parameters at the laboratory scale. The proposed design concept, mechanisms, interactive control interface, and tracking accuracy have been validated through simulation and experimental results, for ensuring quality concrete prints by the developed printer. Material testing parameters have been evaluated experimentally for modeling various mix-designs. To further evaluate printing performance, simulations of layer deformation in printed structures are conducted using finite element analysis, incorporating non-linear material models and various contact layer interactions. The simulated results of printed layers of different shapes of structures show a close resemblance with the experimental concrete printing trials.

Keywords:

• Dynamic analysis
• finite element analysis
• motion control
• material testing
• contact modeling
• framed gantry robot

Data availability statement

The authors confirm that the data supporting the findings of this study are available within the article. The motion control algorithms and MATLAB codes for this study are available upon a reasonable request.

Acknowledgments

The authors are thankful to the Director CSIR-CBRI Roorkee for motivation and moral support towards this research work. The authors would like to thank Mr. Dinesh Kumar for helping in CAD design, and Mr. Kanti Lal Solanki, Mr. Sameer Yadav, Ms. Nitika Sharma, Mr. Nitesh Malviya, and Mr. Sivam Kumar for helping during experimental trials for 3-D concrete printings. Authors would also like to thanks Dr. S. R. Karade for providing the UTM testing facility.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

This research work is supported by the CSIR, India funded R&D project on “Development and trials of a gantry robot for 3D concrete printing” (Grant no: MLP042204).