Pressure-Based Closed-Loop Feedback Control in Robotic Concrete Additive Manufacturing
Extrusion-based robotic concrete additive manufacturing (RCAM) has emerged as a transformative technology in digital construction. However, one of its core challenges lies in managing material uncertainty under pressure, which often causes geometric inaccuracies during the extrusion process. This study presents an innovative pressure-based closed-loop feedback control system designed to ensure geometric fidelity by dynamically compensating for variations in material flow. By incorporating real-time sensor feedback, the system enables more consistent and reliable deposition of concrete filaments, advancing precision in automated construction.
Material Uncertainty and Its Impact on Geometric Fidelity
Material uncertainty in RCAM primarily arises from the variable rheological behavior of concrete mixtures influenced by temperature, moisture, and mix composition. Such inconsistencies lead to irregular extrusion pressure, which directly affects filament geometry, including width and height. Understanding these material variations is essential for achieving accurate layer deposition and maintaining structural stability in printed elements.
Development of Pressure-Based Closed-Loop Control System
The proposed system integrates a real-time pressure monitoring mechanism into the extrusion head, utilizing a load sensor to capture dynamic changes during printing. A feedback algorithm continuously compares the sensed pressure with a reference value, automatically adjusting the extrusion rate to maintain consistent filament geometry. This control strategy establishes a foundation for smart automation in robotic construction.
Experimental Validation and Performance Assessment
To evaluate the control system, extrusion experiments were conducted under both controlled and perturbed conditions. Single and double perturbations were introduced to simulate unpredictable material behavior. Results demonstrated that the system could swiftly recover geometric fidelity—maintaining filament width and height close to the baseline reference—even after multiple disturbances, confirming its robustness and reliability.
Significance of Pressure as a Feedback Parameter
Pressure serves as a highly responsive and sensitive feedback variable in extrusion-based additive manufacturing. Unlike other monitoring parameters, pressure directly reflects material flow dynamics within the nozzle, making it ideal for real-time adjustments. The study highlights pressure’s unique potential as a control metric to mitigate the effects of material uncertainty in RCAM processes.
Future Research Directions
Future investigations should focus on extending this pressure-based control system to more complex printing geometries and varying environmental conditions. Integrating AI-driven prediction models could further enhance control accuracy, enabling adaptive learning for diverse material types. Such advancements would strengthen the foundation for autonomous, high-precision robotic construction technologies.
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