DESC:FIELD
The present disclosure generally relates to formwork panels for casting of concrete structures and more specifically, relates to real-time analyses of the alignment of the formwork panels during the casting of the concrete structure.
DEFINITION
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
AXIAL DEVIATION: The term ‘axial deviation’ used in the context of this disclosure refers to, but is not limited to, the deviation or misalignment of an object with respect to operative X and Y axes, or the misalignment of the object with respect to an operative Z axis or the misalignment or rotation of the object with respect to an operative Y axis.
FORMWORK PANEL: The term ‘formwork panel’ used in the context of this disclosure refers to, but is not limited to, a sheet board or a prefabricated metallic sheet that is used in the construction industry to define a mold to pour cementitious or similar materials therein. It is configured to withstand the side thrust or force of cementitious or concrete material.
These definitions are in addition to those expressed in the art.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
The alignment of formwork is crucial for achieving a smooth concrete finish. Traditionally, this alignment is manually carried out by unskilled laborers on-site and then double-checked by engineers. However, human error often results in small misalignments going unnoticed, leading to uneven surfaces on the concrete structure. Correcting these imperfections typically requires excessive plastering, adding to both material costs and construction time.
Moreover, the consequences of misaligned formwork extend beyond localized surface imperfections. If the misalignment persists across multiple formwork panels during construction, the cumulative deviation can result in the entire building exhibiting an inclined nature with respect to a horizontal reference level. Even minor angular deviations at each floor can compound over multiple stories, leading to a noticeable tilt in the structure when observed from the top floor. This deviation from the intended vertical alignment not only compromises the structural integrity and load distribution of the building but may also pose safety risks, regulatory non-compliance, and aesthetic inconsistencies. Engineers rely on precise alignment to ensure that each floor is constructed perpendicular to the ground level, and any deviation can introduce complexities in subsequent structural elements, such as walls, columns, and facades.
To address these challenges, fixed sensing units have been conventionally employed to monitor and maintain formwork alignment during construction. However, these units come with their own set of drawbacks. Mounting them directly onto the formwork panels instead of the edges complicates their installation and removal processes. Over time, the surface of the formwork panel may bulge out with repeated use. Alternatively, bulging may occur during the manufacturing process, possibly as a result of welding, which may also cause the misalignment of the fixed sensing units due to misaligned welding joints. Additionally, their placement on the panel's surface can disrupt the concrete pouring process, potentially affecting its flow and distribution and compromising the structure's integrity.
Although fixed sensing units offer stability once installed, their rigidity and positioning can pose challenges during setup and concrete pouring. Moreover, the requirement of a dedicated sensing unit for each wall further adds to expenses, making them impractical for large-scale construction projects. In an instance of a multi-storied building, such as a ten-floor building, each formwork panel used in construction would require a sensing unit. Therefore, hundred sensing units would be needed for hundred panels. The need to install and maintain a dedicated sensing unit for every formwork panel significantly increases the financial burden on construction projects. Additionally, the inability to relocate these fixed units limits their efficiency, as they cannot be repurposed for use on other sections of the building once a particular alignment check is completed. This lack of portability further exacerbates the issues of resource optimization, installation complexity, and overall project efficiency.
Thus, there is felt a need for an apparatus for sensing alignment of formwork panels, which alleviates the aforementioned drawbacks of prior art.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels.
Another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which is detachable.
Yet another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which is portable.
Still yet another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which provides easy mounting and removing.
Another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which is cost-effective.
Yet another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which is compact.
Still yet another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which requires a fewer number of sensors for a greater number of formwork panels.
Another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which has IOT.
Yet another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which eliminates the tedious task of manual measurement of alignment of panels.
Still yet another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which provides accessibility to alignment data to all concerned personnel.
Another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which has a relatively higher accuracy.
Yet another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which is versatile.
Still another object of the present disclosure is to provide an apparatus for sensing alignment of formwork panels which is durable.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages an apparatus for sensing the alignment of formwork panels having at least one rail provided thereon. The apparatus comprises a fixture defined by a plate. The plate has a pair of legs extending from an operative rear surface of the plate at a spaced apart distance from each other, to define a gap therebetween for receiving the rail therein. Each leg has at least two holes configured therein.
The apparatus further comprises a plurality of spring-loaded ball plungers configured to be received in the holes. The plungers are configured to detachably secure the fixture on the rail.
The apparatus also comprises a sensing unit attached on an operative front surface of the plate. The sensing unit is configured to sense at least one of the parameters from the group consisting of axial deviations, plumb alignment, rotational misalignment, and level discrepancies of the formwork panel, and is further configured to generate an alert signal if the parameters deviate from predetermined threshold values.
In an embodiment, the fixture includes a pair of ribs connecting the operative rear surface of the plate and the legs.
In another embodiment, the sensing unit includes at least one sensor configured to periodically detect at least one parameter selected from the group consisting of axial deviations, plumb alignment, rotational misalignment, and level discrepancies of the formwork panel. The sensing unit further includes a control unit including a repository configured to store predetermined threshold values corresponding to the parameters; and a processor connected to the sensing unit to fetch the stored predetermined threshold values. The processor is configured to receive the sensed signal, and is further configured to compare the values of the sensed signal with the stored threshold values to generate the alert signal if the parameters deviate from the predetermined threshold values.
In still another embodiment, the control unit includes an analog-to-digital converter configured to convert the sensed signal into a sensed value.
In yet another embodiment, the apparatus includes a display unit configured to communicate with the sensing unit to receive the alert signal, and further configured to display real-time axial deviation, measured alignment data, and/or advertisements based on the alert signal.
In still another embodiment, the control unit includes a communication module configured to communicate with the processor to receive the alert signal, and further configured to transmit sensed alignment data to a remote-control module.
In another embodiment, the sensor is selected from a group consisting of a tilt sensor, an inclinometer, an accelerometer, a gyroscopic sensor, a micro-electro-mechanical system MEMS sensor, a three-axis sensor, a distance sensor including an IR sensors and a laser sensors, a passive RFID-based sensor, and a solar powered sensor.
In still another embodiment, the sensing unit includes an image-capturing unit configured to capture and transmit an image of an identity code provided on the formwork panel to the control unit to facilitate identification of the formwork panel.
In yet another embodiment, the sensing unit includes a sealed enclosure configured to house the sensor and the control unit therein.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
An apparatus for sensing alignment of formwork panels, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
FIGURE 1 illustrates an isometric view of the apparatus for sensing alignment of formwork panels attached on the formwork panels in accordance with the present disclosure ;
FIGURE 2 illustrates an isometric back view of the apparatus for sensing alignment of formwork panels of Figure 1;
FIGURE 3 illustrates an isometric front view of the apparatus for sensing alignment of formwork panels of Figure 1;
FIGURE 4 illustrates an isometric side view of the apparatus for sensing alignment of formwork panels of Figure 1 attached on the formwork panels;
FIGURE 5 illustrates an isometric view of the apparatus for sensing alignment of formwork panels of Figure 1 attached on the formwork panels;
FIGURE 6 illustrates an isometric view of the apparatus for sensing alignment of formwork panels of Figure 1 attached on the formwork panels;
FIGURE 7 illustrates an isometric view of the fixture of the apparatus of figure 1;
FIGURE 8 illustrates a top view of the fixture of the apparatus of figure 1; and
FIGURE 9 illustrates a block diagram of the sensing unit of present disclosure.
LIST OF REFERENCE NUMERALS
10 formwork panel
15 rails
100 apparatus
105 Fixture
105A plate
105B leg
110 spring-loaded ball plunger
115 sensing unit
125 ribs
130 USB port
132 power button
135 display unit
145 sensor
150 analog-digital converter
155 control unit
160 repository
165 processor
DETAILED DESCRIPTION
The present disclosure generally relates to formwork panels for casting of concrete structures and more specifically, relates to real-time analyses of the alignment of the formwork panels during the casting of the concrete structure.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
The present disclosure envisages an apparatus (100) for sensing alignment of formwork panels.
An apparatus (100), of the present disclosure, for sensing alignment of formwork panels (10) will now be described with reference to Figure 1 to Figure 7.
The formwork panels (10) have at least one rail (15) provided thereon.
Figure 1 illustrates an isometric view of the apparatus (100) for sensing alignment of formwork panels (10) of the present disclosure. The apparatus (100) comprises a fixture (105), a plurality of spring-loaded ball plungers (), and a sensing unit (115).
The fixture (105) is configured to securely mount onto the formwork panel (10). The fixture (105) is defined by a plate (105A) with a pair of legs (105B) extending downward from its operative rear surface. The legs (105B) are positioned at a spaced-apart distance from each other, thereby defining a gap between them that is configured to receive the rail (15) of the formwork panel (10). Each of the legs (105B) is provided with at least two holes, strategically positioned to facilitate secure attachment and ensure structural stability. The configuration of the fixture (105) allows for a firm and reliable engagement with the formwork panel, preventing unintended displacement during construction activities.
The fixture (105) is configured with a plurality of spring-loaded ball plungers (110), which are positioned within the holes provided in the legs (105B) of the fixture (105). The spring-loaded ball plungers (110) are configured to facilitate a detachable locking mechanism that securely engages with the rail (15) of the formwork panel (10), ensuring firm and stable positioning of the apparatus during construction. The plungers (110) operate on a press-and-release mechanism, allowing for quick and effortless removal of the fixture when necessary. Each individual plunger (110) can be independently fastened or loosened, enabling precise adjustment of the plunging force or clamping force to accommodate variations in rail (15) dimensions or potential misalignments. The incorporation of these spring-loaded ball plungers (110) significantly improves the portability and reusability of the apparatus (100), streamlining installation and removal processes while increasing overall efficiency in large-scale construction applications.
The spring-loaded ball plunger consists of a threaded housing, an internal compression spring, and a ball tip that serves as the primary contact point with the rail (15) surface. When the apparatus (100) is mounted, the ball presses against the rail (15), causing the internal spring to compress and generate a restoring force that ensures secure engagement. This plunger mechanism provides a stable yet flexible locking function, allowing the fixture (105) to remain firmly attached while permitting easy repositioning when necessary. To detach the apparatus (100), applying pressure to the ball causes it to retract into the housing, momentarily compressing the spring and disengaging the locking mechanism. Upon release, the internal spring expands, pushing the ball back to its original position, thereby restoring the locking function. This self-adjusting feature ensures consistent and repeatable positioning, even in cases where the formwork panel rails exhibit minor misalignments or irregularities. By allowing precise control over the clamping force, the spring-loaded ball plungers facilitate seamless adaptation to different formwork configurations while maintaining a secure hold, enhancing both the reliability and practicality of the apparatus in dynamic construction environments.
The integration of the spring-loaded ball plungers (110) within the fixture (105) allows for seamless attachment and detachment of the apparatus (100), making it highly portable and reusable across multiple formwork panels (10). Unlike traditional fixed alignment monitoring systems that require a dedicated apparatus for each panel, this mechanism enables a single apparatus (100) to be efficiently transferred between different panels as needed. As a result, the requirement for procuring and installing hundreds of sensing units (115) across a large-scale construction project is significantly reduced. This not only minimizes material and operational costs but also streamlines workflow, improving overall efficiency. By facilitating rapid deployment and reusability, the apparatus (100) presents a cost-effective and practical solution for maintaining precise formwork alignment across multiple construction sites without the burden of excessive equipment investment.
The sensing unit (115) is securely attached to an operative front surface of the plate of the fixture. The sensing unit (115) is configured to detect at least one alignment parameter from a group consisting of axial deviations, plumb alignment, rotational misalignment, and level discrepancies of the formwork panel. Upon detecting any deviation from predetermined threshold values, the sensing unit (115) is further configured to generate an alert signal, enabling real-time monitoring and corrective action. This ensures that any misalignment is promptly identified, reducing the risk of structural defects and improving the overall accuracy of formwork positioning.
In an embodiment, the fixture (105) is structurally reinforced with a pair of ribs (125) configured to connect the operative rear surface of the plate (105A) to the legs (105B). These ribs (125) enhance the overall rigidity and stability of the fixture (105), ensuring that it remains securely engaged with the rail (15) of the formwork panel (10) during construction activities. By providing additional structural support, the ribs (125) minimize flexing or deformation of the fixture (105) under load, thereby maintaining consistent alignment and optimal functionality. Furthermore, the integration of ribs (125) contributes to the durability and longevity of the apparatus (100), allowing it to withstand repeated mounting and detachment cycles without compromising the performance of the apparatus (100).
In another embodiment, the sensing unit (115) comprises at least one sensor (145) is configured to periodically detect at least one parameter selected from the group consisting of axial deviations, plumb alignment, rotational misalignment, and level discrepancies of the formwork panel. The sensor (145) operates at predefined intervals to ensure continuous monitoring of the formwork's structural positioning, thereby enabling real-time assessment of any misalignment. The detected data is processed and compared against stored reference values to determine deviations and trigger corrective actions if necessary.
In another embodiment, the sensing unit (115) comprises a control unit (155) including a repository (160) to store predetermined threshold values corresponding to the detected parameters. The repository (160) serves as a reference database, enabling the control unit (155) to compare real-time sensed alignment data with predefined acceptable limits. The repository (160) is configured to store the desired axial values after calibration.
In an embodiment, the sensing unit (115) includes an analog-to-digital converter (150) configured to communicate with the sensor (145) and is further configured to receive the sensed alignment signal from the sensor (145). The sensed alignment signal of the sensor (145) is converted to a digital sensed alignment value by means of the analog-to-digital converter (150).
Furthermore, the control unit (155) includes a processor (165) connected to the sensing unit (115) and configured to retrieve stored predetermined threshold values corresponding to alignment parameters. The processor (165) is further configured to receive the sensed signal from the sensing unit (115) and perform a comparative analysis between the sensed signal values and the stored threshold values. Upon detecting a deviation of the sensed parameters beyond the predetermined threshold values, the processor (165) is configured to generate an alert signal, thereby indicating a misalignment condition.
This alert signal may be further transmitted to a display unit, a remote monitoring system, a cloud server, or a central hub to facilitate real-time corrective action, thereby ensuring the structural integrity and proper alignment of the formwork panels.
In an embodiment, the repository (160) is configured to store therewithin a list of folders containing the scanned and identified panel name or number and the alignment measured for that panel. This information is made accessible to concerned personnel.
In another embodiment, the apparatus (100) is configured to be mounted in between rails (15) of a formwork panel.
In an embodiment, the sensing unit (115) is provided with a display unit (135). In another embodiment, the display unit (135) is configured to display the measured data. The display unit (135) is in communication with the control unit (155) and is configured to display the real-time axial deviation of the formwork formed by the plurality of the formwork panel (10) at a formwork site or a construction site. The display unit (135) is further configured to display measured alignment data, and/or advertisements based on the alert signal.
In an embodiment, the display unit (135) is a touchscreen display.
In another embodiment, the control unit (155) includes a communication module operatively configured to interface with the processor (165). The communication module is configured to receive the alert signal generated by the processor (165) upon detecting a misalignment condition and to transmit the sensed alignment data to a remote-control module. This transmission facilitates real-time monitoring and remote access, allowing authorized personnel to assess structural deviations, implement corrective measures, and maintain the integrity of the formwork panels. If the digital sensed alignment value deviates from the stored axial values, the communication module generates an alert to notify the user. Based on the alert, at least one of the formwork panels (10) may be adjusted to align the sensed alignment signal or the digital sensed alignment value with the stored axial values. The communication module may employ wired or wireless communication protocols to ensure seamless data exchange between the control unit (155) and the remote-control module.
In an embodiment, the sensing unit (115) uses wireless communication technologies such as Bluetooth Low Energy (BLE), Wireless Fidelity (Wi-Fi), Long-term Evolution (LTE), Narrowband Fidelity (NB-Fi), Ultra Narrowband, Low-power Wide-area Network (LoRaWAN), Cellular-based network, Radio frequency identification (RFID), or ZigBee to communicate the sensed alignment signal data with the control unit and from the control unit with the central hub or from the control unit directly with the remote device.
In yet another embodiment, the sensor (145) is selected from a group consisting of a tilt sensor, an inclinometer, an accelerometer, a gyroscopic sensor, a micro-electro-mechanical system (MEMS) sensor, a 3-axis sensor, a distance sensor including an IR sensors and a laser sensors, a passive RFID-based sensor, and a solar powered sensor.
In an embodiment, the sensing unit (115) may be a combination of a 3-axis gyroscope, and a 3-axis accelerometer provided on the same silicon chip, together with an onboard Digital Motion Processor™ (DMP™) to processes complex 6-axis Motion Fusion algorithms.
In another embodiment, the sensing unit (115) is equipped with an image-capturing unit configured to capture and transmit an image of an identity code provided on the formwork panel. The captured image is transmitted to the control unit (155), enabling the identification of the specific formwork panel.
In an embodiment, each formwork is provided with a QR code that can be identified by the sensing unit (115) to identify the panel whose alignment is being sensed and measured. In another embodiment, the apparatus (100) includes an image capturing unit configured to capture the image of the QR code and transmit the image to the processor (165). In another embodiment, the processor (165) is configured to transmit the image of the OQ code along with the alert signal to the display unit, the remote monitoring system, the cloud server, or the central hub to help an operator identify the panel with deviated parameters and facilitate its adjustment.
In another embodiment, the floor panels, i.e., formwork panels (10) fitted right above the floor, can be the major panels of the wall formwork, while the remaining panels can be filler or minor panels, wherein the floor panels can be fitted with the sensing unit (115) of the device of the present disclosure. In an embodiment, the sensing unit (115) includes a sealed enclosure configured to house and protect the sensing unit (115) from the harsh environment in which dust or water may damage the electronic components. The sealed enclosure prevents such ingress of dust or water and safe house the electronics. The enclosure is used to incorporate the different electronic parts, and the battery source is made waterproof by adding a silicone gasket, captive screws, earth screws, and PCB guides to make it waterproof.
In another embodiment, the enclosure has a wall thickness of 1.5 mm to 3.0 mm. In another embodiment, the enclosure is made from a lightweight oxidation-resistant material, selected from Aluminum or like.
In another embodiment, the PCB electronics and other electronics components of the sensing unit (115) are coated with colorless plastic conformal coating spray to protect from the harsh environment of the construction site. The conformal coating “Plastik 70” forms a quick-drying insulating film and thus protects the electronic components from moisture and dust.
In another embodiment, an Automotive grade waterproof 2 Pole SC2102001 male female socket connectors are used for the battery source connection with the electronics.
In an embodiment, a USB port 130 is provided on an operative top surface of the sensing unit (115). In another embodiment, the USB port 130 facilitates the charging of the sensing unit (115). In yet another embodiment, a power button (132) is provided on the operative top surface of the sensing unit (115) in communication with the sensor and the control unit, to actuate the sensor and the control unit.
In an embodiment, the apparatus (100) provides an IOT in the formwork manufacturing process.
In another embodiment, the sensing unit (115) is configured to be mounted between two formwork panels (10) of a plurality of formwork panels.
In another embodiment, the formwork panels are selected from a structure consisting of material aluminum, wood, or in a configuration of a steel frame with a ply as the cover, or a polymer, or a fiber board, or a composite material or any combination thereof.
In an embodiment, the sensing unit (115) has a high resolution and sensitivity to the angle of deviation.
In an embodiment, the plurality of the sensing units (115) is configured to operate in a LOW or HIGH mode. In an embodiment, the status bit is set to HIGH if any of the formwork panel (10) is misaligned and set to LOW if any of the formwork panel (10) is aligned properly in all three axes such as plumb, rotate and diagonal axis.
In an embodiment, the sensing unit (115) is configured to sense the alignment of the horizontal formwork panel (10) with respect to operative X and Y axes. In another embodiment, the sensing unit (115) is configured to sense the alignment of the vertical formwork panel (10) with respect to an operative Z axis.
In an embodiment, the sensing unit (115) is configured to operate in an analog mode, wherein each sensing unit (115) generates a signal of magnitude corresponding to the deviation of the formwork as well as each individual panel of the plurality of the formwork panel.
In another embodiment, the sensing unit (115) is configured to sense the deviation of the formwork as well as each individual panel of the plurality of the formwork panel (10) continuously or periodically in a real-time manner.
In another embodiment, the sensing unit (115) is provided with a noise filter configured to remove chatter and to filter out noise so as to avoid interference between the signals.
In another embodiment, all the sensing unit (115) attached to different panels of the formwork operate on the same frequency band. The sensing unit (115) forms a mesh network and is protected with a unique mesh network ID and mesh password. In additional, every sensing unit (115) is configured with a unique node ID and a chip ID; the node ID is mapped with the chip ID.
In another embodiment, the sensing unit (115) is configured to switch between a sleep mode and a wake-up mode at pre-defined regular intervals of time.
In another embodiment, the sensing unit (115) is battery powered.
In an embodiment, the analog-to-digital converter (150) is an I2C bus.
In another embodiment, the sensing unit (115) can access external sensors such as magnetometers or others through an auxiliary master I²C bus, allowing the sensing units (115) to gather a full set of sensor data without intervention from the system processor (165).
Further, the sensing unit (115) of the present disclosure can be calibrated before installation on the formwork panel. Typically, the inclination is calibrated with respect to gravity. Also, the sensing unit (115) can be calibrated to compensate for vibration in order to provide accuracy for measuring change in deviation in harsh environment at construction sites.
In an embodiment, the central hub is configured to be communicatively connected with the control unit (155). The central hub is being configured to receive the alert from the alerting module and is further configured to transmit the alert to a remote device. The remote device is configured to communicate with the central hub to receive the alert. The remote device is further configured to display and store a statistical and analytical data related to the axial deviation of the formwork formed by the plurality of the formwork panel.
In an embodiment, the remote device is connected to the central hub by means of a wire or wirelessly.
In another embodiment, the remote device is connected with the central hub by means of a cloud server.
In another embodiment, the axial deviation is communicated through wires or wirelessly from the control unit (155) to the remote device or from the central hub to the remote device.
In another embodiment, the remote device is selected from a group consisting of a mobile device, a tablet, or a computer.
In another embodiment, the sensing unit (115) is integrated with an ON/OFF switch and a power source. The ON/OFF switch selectively activates and deactivates the power supply from the power source to operate all electrical components of the sensing unit (115) in connection. Furthermore, the sensing unit (115) is configured with a battery indicator, configured to notify the level of charge remaining in the power source.
In an embodiment, the sensed alignment signal data thus obtained is uploaded from the control unit (155) on the cloud server which is being accessed by the remote device. The data uploaded on the cloud server is accessible to users by means of an application interface. The application interface retrieves the axial deviation data from the cloud server and converts the data into a desired readable format. A registered user of the application interface may be engineers, on-site construction supervisors, and even workers who can access the data either on-site or remotely by means of a suitable remote device. The application interface is installable and executable in the remote device associated with the registered user. The interface is configured to communicate with the cloud server to receive and display the statistical and analytical data relating to the axial deviation in the alignment of the formwork.
In an embodiment, the cloud server cooperates with the sensing unit (115) through central hub to determine the operating mode and position of each sensing unit (115) in the facility.
In another embodiment, the cloud server includes a data acquisition module, a computing module, a database management engine, and an interface module.
In an embodiment, the database management engine is configured to store the time-stamped data regarding the status of the device. The interface module is configured to cooperate with the computing module to facilitate the presentation of the determined status of the device, the generated notifications, and the status reports on at least one of the admin interfaces and the application interface.
In an embodiment, the cloud server enables the registered user to edit the pre-determined number of apparatus required in the formwork via at least one of the admin interfaces and the application interface.
In an embodiment, the sensing unit (115) installed at a facility transmits data to the central hub via a transmitter. In the same manner, all the sensing units are connected to the central hub in a mesh network topology. The central hub acts as a root node and each of the sensing units acts as an intermediate parent node or a leaf node as per its operation status.
In an embodiment, if a sensing unit (115) transmits its own data to the central hub then that particular sensing unit (115), of the plurality of sensing units (115) installed at the facility, operates in the leaf node mode. Similarly, if a sensing unit (115) transfers data of a neighboring sensing unit (115) to the central hub, then that particular sensing unit (115) operates in the intermediate parent node mode.
In an embodiment, the distance between the central hub and the sensing units (115) is calculated based on a signal received straight at the sensing units (115) from the central hub. In this case, the central hub works as an anchor. The sensing units (115) that are operating in the intermediate parent node mode also work as second anchor in this case. Further, the sensing units (115) that are working in the leaf node mode come in between two anchors. Depending on received signal strength indicator (RSSI) at both the anchors, the distance is calculated, and that distance is in centimeters (cm).
In an embodiment, whenever, a sensing unit (115) transmits its sensed signal to the central hub via the transmitter, it also transmits the RSSI and the computed distance value in the data packet. The central hub transmits a consolidated data, containing RSSI and computed distance value from all the sensing units (115) to the cloud server. At the cloud server, the computing module calculates the positions of the sensing units from the received distance value in the respective sensing unit’s (115) data packet. The computing module also determines the operating status/mode (whether leaf node mode and/or intermediate parent node mode) of the sensing units based on the received data. The application interface module facilitates the presentation of the determined operating status/mode of the sensing units on the admin/ application interface.
In an embodiment, the database management engine cooperates with the computing module to identify the anchor locations on a layout provided by the user through the admin interface/ application interface. The interface module and a status detection module work together and mark the location of the sensing unit (115) on the user-provided layout. The interface module facilitates the presentation of the location of all the sensing unit (115) installed in the facility on the mapped layout on the admin interface/ application interface.
In an embodiment, by identifying the axial deviation in the formwork before pouring the cementitious material, the inclination of the formwork can be appropriately adjusted or corrected by referring to the real-time feed of data. Thus, a superior surface finish for the concrete structural members can be achieved.
In an embodiment, the formwork includes at least one major panel and a plurality of minor panels attachable to the major panel. The minor panels are aligned with the major panel, or the minor panels lie in the same plane as that defined by the major panel.
In an embodiment, the sensing unit (115) of the present disclosure is incorporated only in the major panels and the signals generated by the sensing units (115) are recorded and modulated by the control unit (155) as signals corresponding to correct alignment, or the lack thereof, of the entire formwork. Hence, the application interface is configured to display the alignment status of the entire formwork as labeled by the user, wherein the user assigns labels for formwork of walls, roofs, pillars, staircases and so on, to be erected at a given construction site.
In an exemplary embodiment, the apparatus (100) is configured to be portable, allowing for its removal and reattachment between different formwork panels (10) as required. The portability of the apparatus (100) enables flexible deployment across multiple formwork panels (10) within a construction site, ensuring efficient alignment monitoring without necessitating a dedicated sensing unit for each panel. The apparatus (100) can be detached from a first formwork panel and subsequently mounted onto a second formwork panel using the provided mounting provisions, facilitating repeated usage across various locations.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an apparatus for sensing alignment of formwork panels that:
• Is detachable;
• provides easy mounting and removing;
• is cost-effective and compact;
• has IOT;
• has IOT based functionality;
• eliminates the tedious task of manual measurement of alignment of panels;
• provides accessibility to alignment data to all concerned personnel;
• relatively higher accuracy;
• is versatile and durable; and
• requires a fewer number of sensors for a greater number of formwork panels.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation ,CLAIMS:WE CLAIM:
1. An apparatus (100) for sensing the alignment of formwork panels (10) having at least one rail (15) provided thereon, said apparatus (100) comprising:
• a fixture (105) defined by a plate (105A) having a pair of legs (105B) extending from an operative rear surface of said plate (105A) at a spaced apart distance from each other to define a gap therebetween for receiving the rail (15) therein, each leg (105B) having at least two holes configured therein;
• a plurality of spring-loaded ball plungers (110) configured to be received in said holes, said plungers (110) configured to detachably secure said fixture on said rail (15); and
• a sensing unit (115) attached on an operative front surface of said plate (105B), said sensing unit (115) configured to sense at least one of the parameters from the group consisting of axial deviations, plumb alignment, rotational misalignment, and level discrepancies of the formwork panel, and further configured to generate an alert signal if said parameters deviate from predetermined threshold values.
2. The apparatus (100) of claim 1, wherein said fixture (105) includes a pair of ribs (125) connecting said operative rear surface of said plate (105A) and said legs (105B).
3. The apparatus (100) of claim 1, wherein said sensing unit (115) includes:
o at least one sensor (145) configured to periodically detect at least one parameters selected from the group consisting of axial deviations, plumb alignment, rotational misalignment, and level discrepancies of the formwork panel; and
o a control unit (155) including:
? a repository (160) configured to store predetermined threshold values corresponding to said parameters; and
? a processor (165) connected to said sensing unit (115) to fetch said stored predetermined threshold values, said processor (165) configured to receive said sensed signal. and further configured to compare the values of said sensed signal with said stored threshold values to generate said alert signal if said parameters deviate from said predetermined threshold values.
4. The apparatus (100) of claim 1, wherein said control unit (155) includes an analog-to-digital converter (150) configured to convert said sensed signal into a sensed value.
5. The apparatus (100) of claim 1, which includes a display unit (135) configured to communicate with said sensing unit (115) to receive said alert signal, and further configured to display real-time axial deviation, measured alignment data, and/or advertisements based on said alert signal.
6. The apparatus (100) of claim 1, wherein said control unit (155) includes a communication module configured to communicate with said processor (165) to receive said alert signal, and further configured to transmit sensed alignment data to a remote-control module.
7. The apparatus (100) as claimed in claim 1, wherein said sensor (145) is selected from a group consisting of a tilt sensor, an inclinometer, an accelerometer, a gyroscopic sensor, a micro-electro-mechanical system MEMS sensor, a three-axis sensor, a distance sensor including an IR sensors and a laser sensors, a passive RFID-based sensor, and a solar powered sensor.
8. The apparatus (100) of claim 1, wherein said sensing unit (115) includes an image-capturing unit configured to capture and transmit an image of an identity code provided on the formwork panel (10) to said control unit (155) to facilitate identification of the formwork panel.
9. The apparatus (100) of claim 1, wherein said sensing unit (115) includes a sealed enclosure configured to house said sensor (145) and said control unit (155) therein.

Dated this 20th Day of March 2025

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI