Robust bead width manipulation and control for military additive construction operations in expeditionary environments

Kuipers, Kurtis

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https://hdl.handle.net/2142/115709 Copy

Description

Title

Robust bead width manipulation and control for military additive construction operations in expeditionary environments

Author(s)

Kuipers, Kurtis

Issue Date

2022-04-27

Director of Research (if dissertation) or Advisor (if thesis)

Alleyne, Andrew G

Department of Study

Mechanical Sci & Engineering

Discipline

Mechanical Engineering

Degree Granting Institution

University of Illinois at Urbana-Champaign

Degree Name

M.S.

Degree Level

Thesis

Keyword(s)

• additive manufacturing
• 3D printing
• concrete
• mortar
• cement
• CERL
• additive construction
• control
• US Army

Abstract

Since the introduction of large-scale additive manufacturing with cement-based materials, there has been a need to develop robust control systems to improve the accuracy and increase the automation capabilities of the manufacturing process. In this thesis, a robust control system is developed to manipulate the width of the extruded concrete bead while printing. The system is designed to work with a printer that is intended for use in expeditionary, military environments. The system generates a process map that correlates the width of the extruded concrete bead to the velocity of the gantry printer. To accomplish this, a calibration print is designed that varies the gantry velocity along the print path and holds a constant pump speed. After the calibration print is printed, an advanced scanning apparatus is used to the measure the bead width along the entire print. A process map is then generated from the resulting measurements. From the process map, desired printing parameters are selected and input into the G-code to achieve the desired bead width. This method enables military operators to select multiple bead widths to be implemented in prints regardless of the rheological properties of the cement-based material that is being extruded. The end result of this robust control system is the ability to manipulate the bead width during large-scale additive construction prints to within ± 1/4”, on average. Furthermore, the entire process from the start of the calibration print to the implementation of new printing parameters is completed in less than 5 minutes.

Graduation Semester

2022-05

Type of Resource

Thesis

Copyright and License Information

Copyright 2022 Kurtis Kuipers

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