Building material delivery

Abstract

A robotic construction system for building a building, the system comprising a base, a boom extending from the base, and an articulated feed head located near one end of the boom, comprising a nozzle configured to convey building material, and a controller configured to control movement of the boom and the feed head, thus, the nozzle is moved and the building material is conveyed. Wherein the arm support has a slow dynamic response in a large distance, and the feeding head provides a fast dynamic response in a small distance.

Description

Technical Field

[0001] The present invention relates to a system for conveying building materials. In certain cases, the present invention can be used for 3D building printing, concrete pumping and conveying, and leveling. Background Art

[0002] References to any prior publication (or information derived therefrom) or any known matter in the present specification are not and should not be regarded as confirmation or acknowledgement or as implying in any form that the prior publication (or information derived therefrom) or known matter constitute part of the common general knowledge in the field covered by the present specification.

[0003] 3D printing for construction by extruding cement-based materials is a well-known technique. Typically, these extruders work on a gantry system, or if mounted on an articulated arm, the arm has a small travel area. In addition, the material is delivered through a rubber or flexible hose, which is usually passed through a cable chain along a linear axis, or suspended from a mast. Rubber hoses are small in diameter, relatively heavy and expensive, and are not particularly durable and have limited pressure capabilities (relative to steel or metal pipes). The low pressure capabilities and small diameter of the hoses limit the distance that the construction material can be pumped, and also restrict the rheology and aggregate size of the material that can be pumped. As a result, these materials are more expensive than commercial concrete.

[0004] Concrete pumps usually have a large, articulated boom of 4 or 5 sections, in a Z-fold or roll-fold configuration. Concrete is transported along the boom via steel pipes that pass through the boom joints via swivel connections. Typically, the concrete is ultimately transported via a rubber hose at the end of the boom. The hose is usually suspended vertically. The long, light structure results in a relatively flexible boom structure with a low natural frequency. The boom is usually controlled by a hydraulic system. The hydraulic system usually has active damping elements to reduce the bounce of the boom. The action must be slow and controlled so that the boom does not bounce excessively or dangerously. Even so, the movement of the boom end is not very precise, so the operator is allowed to deflect the nozzle at the end of the long suspended rubber hose by up to 1m or so to place the concrete in the desired location.

[0005] The invention aims to combine the setup speed, reach and durability of concrete pump arms and steel tube concrete delivery with the dexterity of a 3D printer to enable automated or remotely controlled placement of 3D printed materials or concrete. Summary of the invention

[0006] Broadly speaking, one aspect of the present invention is intended to provide a robotic construction system for constructing a building, the construction system comprising: a base; a boom extending from the base; an articulated feeder head connected near the end of the boom, the feeder head comprising a nozzle configured for delivering building materials; and a controller configured to control the movement of the boom and the feeder head, thereby moving the nozzle and delivering the building materials, wherein the boom has a slower dynamic response over larger distances and the feeder head provides a faster dynamic response over smaller distances.

[0007] In one embodiment, the controller is configured to control the feed head to dynamically stabilize the nozzle to correct for unintentional movement of the boom end.

[0008] In one embodiment, the controller is configured to control the boom and the delivery head to control movement of the nozzle during delivery of building material.

[0009] In one embodiment, the controller is configured to control the boom and the delivery head to deliver the building material along a desired delivery path.

[0010] In one embodiment, when conveying building materials, the controller is configured to: control the boom to move the boom end to provide a rough guiding movement of the nozzle relative to the conveying path; and control the feed head to move the nozzle to provide precise positioning of the nozzle when the nozzle moves relative to the conveying path.

[0011] In one embodiment, the controller is configured to control the boom and the feed head to move the nozzle relative to at least a portion of the delivery path as the building material is continuously delivered.

[0012] In one embodiment, the delivery head is articulated on two axes, moving the nozzle with two degrees of freedom, thereby allowing the nozzle to be moved in two orthogonal spatial directions.

[0013] In one embodiment, the two orthogonal spatial directions are one of: a horizontal spatial direction to correct for longitudinal and lateral movement of the end of the boom; a horizontal direction and a vertical direction to correct for longitudinal and vertical movement of the end of the boom; and a horizontal direction and a vertical direction to correct for lateral and vertical movement of the end of the boom.

[0014] In one embodiment, the delivery head is articulated on three axes to move the nozzle with three degrees of freedom, thereby allowing the nozzle to be moved in orthogonal spatial directions.

[0015] In one embodiment, movement of the nozzle in orthogonal spatial directions is used to correct for longitudinal, lateral and vertical motion of the boom end.

[0016] In one embodiment, the feed head is articulated on an axis to provide one of the following functions: pitch, roll, pitch motion; pitch, pitch, roll motion; and pitch, roll and slide motion.

[0017] In one embodiment, the feed head is further hinged on another axis to adjust the spacing of the nozzles.

[0018] In one embodiment, the feed head is hinged on another axis to adjust the direction of the nozzle.

[0019] In one embodiment, the feed head is articulated using at least one of: a rotary actuator; a linear actuator; a hydraulic motor; an electric motor; a hydraulic cylinder; an electric punch; a hydraulic servo system; and an electric servo system.

[0020] In one embodiment, the system employs one of: a substantially vertical arrangement of the nozzles to deliver the building material downwardly onto the surface; and a substantially horizontal arrangement of the nozzles to deliver the building material laterally onto the surface.

[0021] In one embodiment, the delivery head comprises a robotic arm and an end effector, wherein the nozzle is supported by the end effector.

[0022] In one embodiment, the delivery head includes a working component for performing an operation on the delivered building material.

[0023] In one embodiment, the working component includes one of the following: a leveling component; a spatula; a template; a mold; a biasing member configured to push the working material; a cutting tool; a grinding head; a polishing head; a washer head; a sandblasting head; and a cutter.

[0024] In one embodiment, the feed head is articulated to perform at least one of the following operations: independently move the working part and the nozzle; move the working part relative to the nozzle; rotate the working part around the nozzle; control the height of the working part relative to the nozzle; and control the direction of the working part.

[0025] In one embodiment, the feed head is articulated about three axes to maintain the working component in a fixed orientation and to provide further articulation to allow adjustment of the height and / or position of the working component.

[0026] In one embodiment, the feed head is articulated to allow rotation and horizontal movement of the working member.

[0027] In one embodiment, the system includes a boom actuator configured to move the boom.

[0028] In one embodiment, the boom actuator is configured to perform at least one of the following functions: rotating the boom; extending or retracting the boom; deploying the boom; and raising or lowering the boom.

[0029] In one embodiment, the system includes a tracking system configured to measure the position and / or motion of at least one of: a feed head; an arm end; an arm; and a nozzle; and the controller is configured to control the feed head based on signals from the tracking system.

[0030] In one embodiment, the tracking system includes at least one of: a laser guide; a physical guide and corresponding guidance sensor; a positioning sensor; a GPS sensor; a motion sensor; an inertial measurement unit; a machine vision system; a laser tracker; a lidar; a radar; a ranging sensor; and an ultrasonic ranging sensor.

[0031] In one embodiment, the tracking system includes: three retroreflectors mounted near the end of the boom; and a corresponding laser tracker, wherein the tracking system is configured to measure the position and orientation of the boom end based on rays reflected from the retroreflectors.

[0032] In one embodiment, the tracking system includes: a retroreflector movably mounted on an articulated head proximate the nozzle; and a laser tracker, wherein the tracking system is configured to measure the position and orientation of the nozzle based on rays reflected from the retroreflector.

[0033] In one embodiment, the tracking system includes: a laser guide located in the environment; and a sensor mounted on at least one of the boom and the feed head, the sensor being configured to detect deviations from the laser guide.

[0034] In one embodiment, the laser guide defines at least one of: a height plane; and a transport path.

[0035] In one embodiment, the system includes a feed tube configured to transport building material from the base along the boom to the nozzle.

[0036] In one embodiment, the feed tube comprises an articulated steel tube.

[0037] In one embodiment, at least one of the feeding pipe and the arm is formed by hingedly connecting the feeding pipe.

[0038] In one embodiment, the system includes a hopper configured to receive a building material and a pump configured to pump the building material from the hopper through a conduit.

[0039] In one embodiment, a pump includes: two pump cylinders; an associated swing valve disposed on each pump cylinder, wherein adjustment of the position of the swing valve determines whether the pump cylinder is filling or discharging material; and a controller configured to deliver building material by: partially emptying one pump cylinder while the other pump cylinder is filling; and increasing the delivery rate of one pump cylinder while decreasing the delivery rate of the other pump cylinder, thereby maintaining an overall delivery rate when switching delivery between the two pump cylinders.

[0040] In one embodiment, the pump includes: a first cylinder body, which includes a first piston driven by a first actuator, the first cylinder body being configured to fill the building material when the first piston is retracted from the first cylinder body and to deliver the building material when the first piston is extended into the first cylinder body; a second cylinder body, which includes a second piston driven by a second actuator, the second cylinder body being configured to fill the building material when the second piston is retracted from the second cylinder body and to deliver the building material when the second piston is extended into the second cylinder body; a first swing valve connecting the first cylinder body to a feed pipe in a delivery position and allowing the building material to enter the first cylinder body in a filling position; a second swing valve connecting the second cylinder body to the feed pipe in a delivery position and allowing the building material to enter the second cylinder body in a filling position; a pump controller configured to control the first actuator and the second actuator and the first swing valve and the second swing valve to achieve: partially emptying one pump cylinder while the other pump cylinder is filling and delivering the building material; transitioning from one pump cylinder to another pump cylinder by reducing the delivery rate of one pump cylinder while increasing the delivery rate of another pump cylinder, thereby maintaining the overall delivery rate.

[0041] In one embodiment, the pump controller is configured to: initially: position the first swing valve in the filling position and retract the first piston to fill the first cylinder; position the first swing valve in the delivery position and begin to extend the first piston to begin to deliver building material from the first cylinder; in the first step: continue to extend the first piston to continue to deliver building material from the first cylinder; position the second swing valve in the filling position and retract the second piston to fill the second cylinder; in the second step, once the second cylinder is full of building material, then: reduce the rate of extending the first piston to deliver the remaining building material from the first cylinder; position the second swing valve in the delivery position In a third step, once the first cylinder is emptied, the first swing valve is positioned in the filling position and the first piston is retracted to fill the second cylinder; the second piston is continued to be extended to continue to transport the building material from the second cylinder; in a fourth step, once the first cylinder is full of building materials, the first swing valve is positioned in the transport position and the first piston is begun to be extended at an increasing rate to start transporting the building material from the first cylinder; the rate of extending the second piston is reduced to transport the remaining building material from the second cylinder; and steps one to four are repeated as needed.

[0042] In one embodiment, the building material includes at least one of: a viscous fluid; a cement-based material; concrete; cement; mortar; shotcrete; a 3D printing material; and a polymeric material.

[0043] In one embodiment, the base is part of a vehicle.

[0044] In broad terms, another aspect of the present invention is directed to a building material pump comprising: two pump cylinders; an associated swing valve disposed on each pump cylinder, wherein adjustment of the position of the swing valve determines whether the pump cylinder is filling or discharging material; and a configured controller for delivering building material by: partially emptying one pump cylinder while the other is being filled; and by reducing the delivery rate of one pump cylinder while increasing the delivery rate of the other pump cylinder, thereby maintaining the overall delivery rate when switching delivery between the two pump cylinders.

[0045] In one embodiment, the pump includes: a first cylinder body, which includes a first piston driven by a first actuator, the first cylinder body being configured to fill the building material when the first piston is retracted from the first cylinder body and to deliver the building material when the first piston is extended into the first cylinder body; a second cylinder body, which includes a second piston driven by a second actuator, the second cylinder body being configured to fill the building material when the second piston is retracted from the second cylinder body and to deliver the building material when the second piston is extended into the second cylinder body; a first swing valve connecting the first cylinder body to a feed pipe in a delivery position and allowing the building material to enter the first cylinder body in a filling position; a second swing valve connecting the second cylinder body to the feed pipe in a delivery position and allowing the building material to enter the second cylinder body in a filling position; a pump controller configured to control the first actuator and the second actuator and the first swing valve and the second swing valve to achieve: partially emptying one pump cylinder while the other pump cylinder is filling and delivering the building material; transitioning from one pump cylinder to another pump cylinder by reducing the delivery rate of one pump cylinder while increasing the delivery rate of another pump cylinder, thereby maintaining the overall delivery rate.

[0046] In one embodiment, the pump controller is configured to: initially: position the first swing valve in the filling position and retract the first piston to fill the first cylinder; position the first swing valve in the delivery position and begin to extend the first piston to begin to deliver building material from the first cylinder; in the first step: continue to extend the first piston to continue to deliver building material from the first cylinder; position the second swing valve in the filling position and retract the second piston to fill the second cylinder; in the second step, once the second cylinder is full of building material, then: reduce the rate of extending the first piston to deliver the remaining building material from the first cylinder; position the second swing valve in the delivery position In a third step, once the first cylinder is emptied, the first swing valve is positioned in the filling position and the first piston is retracted to fill the second cylinder; the second piston is continued to be extended to continue to transport the building material from the second cylinder; in a fourth step, once the first cylinder is full of building materials, the first swing valve is positioned in the transport position and the first piston is begun to be extended at an increasing rate to start transporting the building material from the first cylinder; the rate of extending the second piston is reduced to transport the remaining building material from the second cylinder; and steps one to four are repeated as needed.

[0047] In one embodiment, the pump includes: a first sensor configured to measure the position of the first piston; and a second sensor configured to measure the position of the second piston, wherein the controller can control the first actuator and the second actuator according to the signals from the first sensor and the second sensor. It should be noted that the broad forms of the present invention and their respective features can be used in combination and / or independently, and the mention of a single broad form is not intended to limit the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Various examples and embodiments of the present invention will now be described with reference to the accompanying drawings, in which: Figure 1A is a schematic diagram of a system for conveying building materials; Figure 1B yes Figure 1A A schematic plan view of the system; Figure 2 yes Figure 1A A schematic diagram of an example of a control system of a system; Figure 3 is a schematic diagram of yet another example of a system for conveying building materials; Figure 4 is a schematic diagram of an example of a feeding head; Figure 5 is a schematic diagram of another example of a feeding head; Figure 6 is a schematic diagram of another example of a feeding head combined with a robot arm; Figure 7 yes Figure 6 Schematic diagram of the end effector of the robotic arm; Figure 8 is a schematic diagram of an example of a replacement head for a block laying machine using a triple tracker tracking system; Fig. 9 is a schematic diagram of an example of a replacement head for a block laying machine using a single tracker tracking system; Fig.10 is a schematic diagram of an example 3D printer; Fig.11 is a schematic diagram of an alternative example of a 3D printer; Figure 12 to Figure 14 is a schematic diagram of an example of a feed head articulation for a material delivery system; Fig.15A is a schematic diagram of an example of an articulated feed head of a material conveying system; Fig. 15B is a schematic diagram of an example of an articulated feed head of a material conveying system; Figures 16 to 22 is a schematic diagram of a further example of a feed head articulation for a material delivery system; Fig.23A is an end view of an example of a known construction of a concrete pump; Fig. 23B yes Fig.23A The plan view of the concrete pump; Fig.24 is a top end view of an example of a concrete pump; Fig.25A is a schematic diagram of an example of a system for processing building materials; Fig.25B yes Fig.25A Schematic diagrams of alternative views of a working machine; Fig.25C Includes leveling rod working parts Fig.25A A schematic diagram of an example of a working head of a working machine; Fig.25D is a schematic diagram of an example of the working parts of a cable tie; Fig.25E is a schematic diagram of an example of the working parts of a helicopter spatula; Fig.26A is a schematic diagram of another example of a system for processing building materials with the boom in a folded position; Fig.26B yes Fig.26A A schematic diagram of a system in which the boom is in an extended position; Fig.26C yes Fig.26A A schematic diagram of a feeding head of a system; Fig.27A is a schematic diagram of an example of a leveling bar including an attachable spatula; Fig.27B is a schematic diagram of an example of a leveling bar including a deployable spatula; Fig.28 is a schematic diagram of an example of a tracking system including a laser level; Fig.29 is a schematic diagram of an example of a boom extension mechanism. DETAILED DESCRIPTION

[0049] The following description explains a variety of different systems and methods for delivering building materials into an environment. For purposes of illustration, the following definitions apply throughout.

[0050] The term "delivery" refers to the distribution of building materials in situ to the desired location, including one or more discrete locations, and continuous or semi-continuous delivery over a defined area or path.

[0051] The term "processing" refers to interacting with building materials, and more typically performing operations on them on site. This usually involves some form of mechanical manipulation, such as moving or shaping building materials, and can include specific tasks such as leveling, troweling, etc. However, this can also include other operations, such as grinding or polishing, as well as cleaning or chemical treatments. Further examples are described in more detail below.

[0052] The term "building material" refers to a material used in construction, and in particular, generally a viscous fluid material that can cure or otherwise solidify in situ to form a part of a building. Examples of building materials include, but are not limited to, cement-based materials such as concrete, cement, mortar, shotcrete, etc., and polymeric materials such as 3D printing materials. These materials may include additives such as fiber reinforcements, and it will be appreciated that a wide variety of building materials are contemplated.

[0053] The term "environment" refers to any location, area, place or space where construction materials can be transported. The type and nature of the environment will vary depending on the preferred embodiment, and the environment can be a specific physical environment or a logical physical environment that is demarcated only because it is the space where interaction occurs. Non-limiting examples of environments include buildings or construction sites, vehicle components (such as the deck of a ship or the loading pallet of a truck), factories, loading sites, ground work areas, etc., and more examples are described in more detail below.

[0054] The term "robotic arm" refers to a programmable mechanical manipulator. In this specification, a robotic arm includes a multi-axis articulated arm, a parallel kinematic robot (e.g., Stewart platform, Delta robot), a spherical geometry robot, a Cartesian robot (a robot with orthogonal axes of linear motion), etc.

[0055] The term "feeding head" refers to a programmable mechanical manipulator capable of delivering building materials. In this specification, a feeding head may include a mechanical arm or other suitable articulated device capable of positioning a nozzle for delivering building materials.

[0056] The term "working head" refers to a programmable mechanical manipulator capable of handling building materials. In this specification, the working head may include a mechanical arm or other suitable articulated devices capable of positioning a working component to handle building materials.

[0057] When the head performs the dual function of conveying and handling building materials, the head may be considered a working head or a feeding head, and the two terms should be considered interchangeable in this context.

[0058] The term "jib" refers to an elongated supporting structure, such as a revolving jib, with or without a lever or bucket, with or without telescopic elements, a telescopic boom, a telescopic articulated boom. Examples include crane jibs, bulldozer jibs, truck crane jibs, all with or without cable support or cable support elements. A jib may also include an overhead gantry structure, a cantilever gantry, a controlled tension truss (a jib may not only refer to a jib, but also a parallel mobile crane supported by multiple cables (see PAR System, Tension Truss - Chernobyl Crane)), or other movable arms that can be moved to different positions in space.

[0059] The term "end effector" refers to a device located at the end of a robotic arm for interacting with the environment. The end effector may include a clamp, a nozzle, a sandblaster, a spray gun, a wrench, a magnet, a welding torch, a cutting torch, a saw, a milling cutter, a router, a hydraulic shear, a laser, a riveting tool, etc., and the mention of these examples is not meant to limit the present invention.

[0060] The TCP (Tool Centre Point) is a location on the end effector or part of the feed head (e.g. nozzle) whose position and orientation are derivable and controllable. It is usually located at the far end of the kinematic chain. The kinematic chain refers to the link chain and its joints within the feed head and / or between the base of the robot and the end effector.

[0061] CNC (Computer Numerical Control) is used to automate machine processing by executing pre-programmed machine control command sequences through a computer / processor / microcontroller.

[0062] In CNC control systems, the application of coordinate transformations is often to allow programming in a convenient coordinate system. This operation can also be performed to correct for workpiece position errors when the workpiece is clamped in a vise or fixture on a CNC machining center.

[0063] These coordinate transformations are usually applied in a static sense to resolve static coordinate offsets or to correct static errors.

[0064] Robots and CNC machines are programmed in a practical Cartesian coordinate system and use kinematic transformations to convert Cartesian coordinates to joint positions to move the robot or CNC machine's pose.

[0065] Measuring the position of the robot end effector close to the TCP in real time can improve the robot's accuracy. This process is applicable to static end effectors used for probing and drilling. This is achieved through a multi-step process of moving to the programmed position, taking the position measurement, calculating the correction vector, adding the compensation vector to the programmed position, and then moving the TCP to the new position. This process is not done in hard real time, but relies on the pose of the static robot arm.

[0066] Now refer to Figure 1A , 1B and Figure 2 An example system for transporting building materials within a physical environment is described.

[0067] exist Figure 1A In the example of , the system 100 includes a base 141, an arm 142 extending from the base, and an articulated feed head 110 attached near the end of the arm 142, the feed head including a nozzle 113 configured to deliver building materials. The system also provides a controller 130, which controls the movement of the arm 142 and the feed head 110, thereby allowing the movement of the nozzle to be controlled so as to deliver the building materials into the environment.

[0068] Some further example details will now be described to provide context for the above described system, however, it should be understood from the following description that these are example features and are not necessarily meant to limit the invention.

[0069] In this example, the feed head 110 includes a support 111, a robotic arm 112, and a nozzle 113. The feed head 110 is positioned relative to an environment E, which is represented as a two-dimensional plane in this example, but can be a three-dimensional volume of any configuration in practical applications. In use, the nozzle 113 is used to deliver building materials, such as concrete, in the environment E. The specific form of the feed head 110 will vary depending on the preferred implementation, and more examples will be described in more detail later.

[0070] The feed head 110 is supported by a robot base actuator 140, which can be used to move the robot base. In this example, the robot base actuator takes the form of a boom assembly, which includes a boom base 141 and a boom 142 including a plurality of boom elements. The boom is typically adjustable, allowing the position and / or orientation of the robot base to be adjusted. The type of movement available will vary depending on the preferred implementation. For example, the boom base 141 can be mounted on a vehicle, allowing it to be positioned and optionally rotated to a desired position and orientation. The boom 142 can be a telescopic and / or folding arrangement, including a plurality of telescopic / folding boom or rod members, allowing the length of the boom or rod to be adjusted. In addition, the angle between the boom base 141 and the boom 142 and the different elements within the boom 142 can be controlled, for example using components such as hydraulic actuators, thereby allowing the feed head 110 to be set at a desired location in the environment E.

[0071] The system 100 includes a tracking system 120 that is capable of tracking the movement of the feed head, in one example, the movement of the feed head relative to the environment. In one example, the tracking system includes a tracking base 121, which is generally statically positioned relative to the environment E, and a tracking target 122 mounted on a support 111, so that the position of the feed head 110 relative to the environment E can be determined. In addition, other tracking arrangements can also be used. For example, other position / motion sensors, such as an inertial measurement unit (IMU), can be used in addition or alternatively, as described in more detail below. Therefore, the current example is only for illustrative purposes and should not be considered as limiting.

[0072] The control system 130 is arranged to communicate with the feed head 110, and optionally with the tracking system 120, allowing the feed head to be controlled optionally based on signals received from the tracking system. The control system typically includes one or more control processors 131 and one or more memories 132. For ease of explanation, the following description will refer to one processing device and one memory, but it will be understood that multiple processing devices and / or memories may be used, and any component may include a plural configuration. In use, the memory typically stores control instructions in the form of application software or firmware, which are executed by the processor 131, thereby allowing the signals from the tracking system 120 and the robot assembly 110 to be interpreted and used to control the robot assembly 110 to perform interactive operations.

[0073] Figure 2 An example of control system 130 is shown in greater detail.

[0074] In this example, the control system 230 is connected to a feed head controller 210, a tracking system controller 220 and an arm controller 240. The feed head controller 210 is connected to one or more actuators 211, 212, which can control the positioning of the nozzle 113. The tracking system controller 220 is connected to the tracking head 221 and the target 222 so that the tracking system is controlled and the relative position of the tracking head 221 and the target 222 can be determined and returned to the control system 230. The arm controller 240 is typically connected to the arm actuators 241, 242, which can be used to position the arm and thus the robot base. In addition, a second tracking system 225 can be provided in addition and / or alternatively, and the second tracking system 225 includes sensors 226, such as inertial sensors, which are optionally connected to a controller or processor. It should be understood that, in practice, the feed head and the arm may have multiple actuators, such as servo motors, hydraulic cylinders, etc., to achieve the movement of their respective axes (ie, joints), and the mention of a single actuator does not mean to limit the present invention.

[0075] Any of the manipulator controller 210, the tracking system controller 220, the second tracking system 225, and the arm controller 240 generally includes an electronic processing device, which, in conjunction with the stored operating instructions, is responsible for interpreting the commands provided by the control system 230 and generating control signals for the corresponding actuators and / or tracking systems, and / or receiving signals from sensors and providing relevant data to the control system 230. The electronic processing device may include any electronic processing device, such as a microprocessor, a microchip processor, a logic gate configuration, firmware optionally associated with the implementation logic, such as an FPGA (field programmable gate array), or any other electronic device, system or configuration. It should be understood that the manipulator controller 210, the tracking system controller 220, and the arm controller 240 generally constitute components of the arm assembly, the robot assembly, and the tracking system, respectively. Since the operation of such a system can be understood by those skilled in the art, these systems will not be described in detail.

[0076] The control system 230 typically includes an electronic processing device 231, a memory 232, an input / output device 233, and an interface 234, which can be used to connect the control system 230 to the robot controller 210, the tracking system controller 220, and the arm controller 240. Although only a single external interface is shown, this is for illustrative purposes only, and in practice multiple interfaces of different types (e.g., Ethernet, serial, USB, wireless, etc.) may be used.

[0077] In use, the processing means 231 executes instructions stored in the memory 232 in the form of application software to allow the required processing to be performed. The application software may include one or more software modules and may be executed in a suitable execution environment, such as an operating system environment.

[0078] Thus, it should be understood that the control system 230 may be formed by any suitable processing system, such as a suitably programmed PC, computer server, etc. In one particular example, the control system 230 is a standard processing system, such as an Intel architecture-based processing system, which executes a software application stored on a non-volatile (e.g., hard disk) memory, although this is not required. However, it should also be understood that the processing system may be any electronic processing device, such as a microprocessor, a microchip processor, a logic gate configuration, firmware optionally associated with implementation logic such as an FPGA (field programmable gate array), or any other electronic processing device, system or arrangement.

[0079] It should also be understood that the arrangements described above are for illustrative purposes only, and that a variety of different systems and associated control configurations may be utilized in practice. For example, it should be understood that the processing distribution between controllers and / or control systems may vary according to preferred embodiments.

[0080] Examples of systems for laying blocks are described in US8166727, WO2009 / 026641, WO2009 / 026642, WO2018 / 009981, WO2018 / 009986, WO2019 / 014701 and US20210379775, the contents of which are incorporated herein by cross-reference. However, in this example, the device is not for laying blocks, but is configured for processing building materials through working parts, which in turn leads to many different factors that affect implementation.

[0081] Typically, the boom assembly can have considerable length, so for example in the case of construction applications, the boom may need to span across the building site and may be tens of meters in length. In this case, the boom is often subject to a variety of loads, including forces due to the movement of the boom and / or feeder head, construction material conveyed along the boom, wind loads, mechanical vibrations, etc., which in turn may cause oscillations or other movements at the end of the boom, resulting in movement of the robot base relative to the environment. This movement is often referred to as unintentional movement (unintentional movement).

[0082] In addition, the feed head can be moved in a controlled manner by actively moving the boom. This is often performed to move the nozzle during material delivery, such as laying building materials along a path such as on top of a wall or other structure, and this movement is often referred to as intentional movement.

[0083] Additionally, due to the relative sizes, particularly on the order of tens of meters for the boom and a meter or less for the feed head mechanism, any movement of the boom is necessarily slower than movement of the feed head.

[0084] Therefore, in practice, when using the system, it is usually necessary to guide the nozzle so as to deliver the building material to a specific building location or area. For example, when building a wall, it is usually necessary to guide the nozzle multiple times along the expected range of the wall, so that the wall is gradually built by the building material. It can be understood that it is performed in a manner similar to 3D printing.

[0085] In this process, the coarse movement of the nozzle is achieved by moving the arm, such as by rotating the arm and adjusting the arm length, so that the nozzle roughly traverses the expected delivery path. At the same time, the feed head 110 can be controlled to provide fine position adjustment and specifically ensure that the nozzle follows the expected delivery path. This is performed both to combat unintentional movement of the end of the arm and to overcome the limitation of the ability to precisely control the end of the arm by moving the arm alone.

[0086] It will therefore be appreciated that in the above arrangement the boom moves with a slower dynamic response over a larger distance, while the feed head provides a faster dynamic response over a smaller distance, and the controller controls both the boom and the feed head to move the nozzle to deliver building material.

[0087] For clarity, the terms "larger" and "smaller" as described above are relative, so a "slower dynamic response" is simply slower than a "faster dynamic response" and a "larger distance" is simply greater than a "smaller distance".

[0088] In any case, it can be appreciated that a combination of fine and rapid response of the feed head can be used to address limitations in the ability to precisely control the end of the boom, and also to address problems with unintentional movement of the end. Applicants refer to this form of operation as Dynamic Stabilization Technology (DST), and it has been described in prior publications, including US8166727, WO2009 / 026641, WO2009 / 026642, WO2018 / 009981, and WO2018 / 009986, the contents of which are incorporated herein by cross-reference.

[0089] Examples of a number of different aspects of the above system will now be described in more detail. These different aspects of the system can be used independently or can be used in combination according to preferred embodiments. It will be understood that reference to individual aspects should not be considered limiting, and these aspects can be used in any number of different combinations depending on the preferred implementation and the scenario in which the system is used.

[0090] As described above, the controller may be configured to control the boom and the feed head to control movement of the nozzle during delivery of building material, in particular, for example, to deliver the building material along a desired delivery path. This typically involves having the controller control the boom so as to move the end of the boom to provide a rough guiding movement of the nozzle relative to the delivery path, while controlling the feed head to move the nozzle to provide precise positioning of the nozzle as it moves relative to the path. This in turn allows continuous or at least substantially continuous delivery of building material as the nozzle moves, thereby ensuring continuity of building material within the resulting building.

[0091] In order to achieve the desired control, the feed head is usually articulated on at least two axes to allow movement of the nozzle in two orthogonal spatial directions. In this regard, it should be understood that minimizing the articulation freedom of the feed head will reduce the complexity of the feed head, but may be at the expense of limiting the accuracy of positioning the nozzle in other spatial directions or orientations. Therefore, the specific configuration of the feed head can vary depending on the specific usage scenario.

[0092] For example, the feed head may be configured to move the nozzle in the horizontal spatial direction to correct for longitudinal and lateral movement of the boom end. This allows correction and / or compensation for rotation and extension / retraction movement of the boom. In this example, vertical movement of the boom is not compensated, but this may be less important in some cases, such as if the system is delivering building materials vertically down onto a surface or other structure. In this case, rough positioning of the nozzle in the vertical direction may provide sufficient accuracy, so that only position adjustment in the horizontal direction is required.

[0093] Alternatively, the axes may allow position adjustment in one horizontal direction and one vertical direction to correct for longitudinal or lateral movement of the boom end as well as vertical movement. In this case, accurate compensation can be provided for extension / retraction or rotation of the boom and boom end height.

[0094] In other applications, the feed head may be articulated in three axes so that the nozzle has three degrees of freedom for movement, thereby allowing the nozzle to move in orthogonal spatial directions, which can be used to correct longitudinal, lateral and vertical movement of the nozzle.

[0095] To provide three degrees of motion, the feed head may be articulated in a variety of ways, for example, providing the feed head with an axis to provide one of: pitch, roll, pitch motion; pitch, pitch, roll motion; and pitch, roll and slide motion. Further examples of such arrangements are described in more detail below.

[0096] Although not required, in some arrangements the feed head may be articulated on another axis (or a third axis in a two-dimensional motion arrangement) to adjust the spacing of the nozzles. Typically, the adjustment of nozzle spacing is less critical when conveying building materials, for example, the nozzle spacing can be varied depending on the orientation of the other axis without adversely affecting the transport of the building material. Likewise, the feed head may be articulated on another axis to adjust the orientation of the nozzles (e.g., to adjust yaw and / or roll).

[0097] However, this is not required and a fixed nozzle orientation and pitch may be used, for example with the nozzles arranged substantially vertically to deliver building material downwardly onto a surface, or with the nozzles arranged substantially horizontally to deliver building material laterally onto a surface, for example when spraying concrete walls, embankments etc.

[0098] The feed head may be articulated using a variety of different devices, including any one or more of a rotary actuator; a linear actuator; a hydraulic motor; an electric motor; a hydraulic ram; an electric ram; a hydraulic servo system; and an electric servo system, or the like. The exact nature of the actuator will vary depending on the preferred embodiment, and some examples are described in more detail below.

[0099] In one example, the feed head includes a robotic arm and an end effector, and wherein the nozzle is supported by the end effector, although this is not required, and in other examples, the nozzle is integrated directly into the feed head without a separate end effector.

[0100] In one example, the feed head includes working parts for processing the delivered building material. In this regard, in addition to simply delivering the material, additional actions may be required to shape or otherwise arrange the material. Such examples include leveling the material to ensure a level surface, or shaping the material to form a specific shape as the material cures or otherwise solidifies. Exemplary working parts include, but are not limited to, leveling parts; spatulas; templates; molds; biasing members configured to push the work material; cutting tools; grinding heads; polishing heads; washer heads; sandblasting heads; and cutters, etc.

[0101] The working part can be arranged in a fixed arrangement relative to the nozzle, which may be sufficient to ensure that the desired work is achieved depending on the use scenario, for example, a template can be attached to the nozzle to shape the building material when delivering the material, for example, to guide the material into a generally rectangular shape for use when building a wall or the like. However, in other examples, the feed head can be articulated to adjust the position of the working part relative to the nozzle. This can be used to move the working part relative to the nozzle, for example to allow the working part to rotate around the nozzle, so that the working part can be provided in a trailing arrangement depending on the direction of movement of the nozzle. This can be used additionally and / or alternatively to control the height of the working part relative to the nozzle, or to maintain a specific orientation of the working part, which is important in the case of leveling, for example.

[0102] In one example, the feed head is articulated about three axes to allow the work piece to be held in a fixed orientation, and another articulation is provided to allow height and / or position adjustment of the work piece. This can ensure that when the arm and / or feed head are moved to change the nozzle position (which may result in some change in the nozzle orientation), the work piece can be held in a particular orientation, such as vertical, while also separately allowing the height of the work piece to be controlled.

[0103] The feed head may also be articulated to allow rotation and horizontal movement of the working component, for example allowing a leveling member to rotate to provide the leveling function, and horizontal movement to ensure that all parts of the surface can be leveled.

[0104] In one example, as described above, the system includes a boom actuator configured to move the boom. This is typically configured to rotate the boom, extend the boom, deploy the boom, or raise or lower the boom, and can be achieved using a hydraulic or servo-electric actuator (e.g., a hydraulic cylinder, a servo motor, or the like).

[0105] As also mentioned above, the system typically includes a tracking system configured to measure the position and / or movement of the feed head, the boom end, the boom and / or the nozzle. In this regard, since the position of the nozzle relative to the boom end is typically known by virtue of the kinematics of the feed head, once one of the above positions is known, the other positions can typically be easily derived. The controller is then typically configured to control the feed head based on the signals from the tracking system.

[0106] The nature of the tracking system will vary depending on the implementation. For example, the tracking system may include any one or more of laser guidance, physical guides and corresponding guidance sensors, positioning sensors, GPS sensors, motion sensors, inertial measurement units, machine vision systems, laser trackers, lidars, radars, range sensors, and ultrasonic range sensors.

[0107] For example, in a particular configuration, the tracking system 120 includes a tracking base 121, which includes a tracker head and a base sensor; the tracker head has a radiation source, which is intended to send a beam of radiation to a target 122; and the base sensor is used to sense the reflected radiation. There is also a base tracking system that tracks the position of the target 122 and controls the orientation of the tracker head to follow the target 122. The target 122 generally includes a target sensor for sensing the radiation, and a target tracking system that tracks the position of the tracking base and controls the orientation of the target to follow the tracker head. Angle sensors are provided in the head and the target to determine the orientation of the head and the target, respectively. The tracker processing system determines the relative position of the tracker base and the target based on the signals from the sensors, and in particular uses the signals from the angle sensors to determine the relative angle of the tracker and the target, and can use the flight time of the radiation beam to determine the physical separation. In another example, the radiation can be polarized so as to determine the orientation of the base relative to the tracking head. Although a single tracking system 120 including a head and a target is shown, this is not required, and in other examples, multiple tracking systems and / or targets can be provided, as described in more detail below.

[0108] For example, the tracking system may include three retroreflectors mounted near the end of the boom and corresponding laser trackers, wherein the tracking system is configured to measure the position and orientation of the end of the boom based on rays reflected from the retroreflectors. Alternatively, the tracking system may include a retroreflector and a laser tracker movably mounted on an articulated head near the nozzle, wherein the tracking system is configured to measure the position and orientation of the nozzle based on rays reflected from the retroreflectors.

[0109] In one specific example, the tracking system is a laser tracking system, with example devices manufactured by API (Radian and OT2 with STS (Smart Tracking Sensor)), Leica (AT960 and Tmac), and Faro. These systems measure position at 300Hz, 1kHz, or 2kHz (depending on the device) and rely on a combination of multiple sensing devices, including laser tracking, vision systems using 2D cameras, accelerometer data from tilt sensors or INS (inertial sensors). It can be used to make precise position measurements, and the data obtained by the laser tracker and the active target is equivalent to the position and optional orientation of the active target relative to the environment E. Since such systems are known and commercially available, they will not be described in detail.

[0110] Such systems offer high accuracy (typically sub-millimeter) and low latency (a few microseconds), making them particularly suitable for scenarios that require high precision. However, in material delivery scenarios, high accuracy may be less important. For example, in some cases, the material may undergo additional processing, such as leveling, so precise positioning of the nozzle is less important. Similarly, in some cases, the work material may roll or slump after delivery, so the positioning of the nozzle may only need to be within a few millimeters or centimeters rather than sub-millimeter accuracy. Due to the high cost of laser tracking systems, a more basic tracking system can be used in these cases. For example, a combination of GPS and IMU may provide sufficient accuracy.

[0111] Alternatively, a laser guide can be placed in the environment and a sensor mounted on the arm, delivery head or nozzle, configured to detect deviations from the laser guide. In this case, the laser guide can be used to define the height plane and / or delivery path. Thus, in this example, a laser beam can be used as a path for the nozzle to move, the optical sensor detects deviations from the beam, and the controller adjusts the delivery head as needed to compensate.

[0112] Typically, the system includes a feed pipe configured to convey building material from the base along the boom to the nozzle. While rubber hoses may be used, they are generally susceptible to wear, particularly as the configuration of the boom changes, resulting in bending of the pipe. Therefore, in other examples, the feed pipe may include an articulated steel pipe.

[0113] Additionally, in some examples, the boom and / or feeder head are formed from an articulated feeder tube such that the tube forms the physical structure of the boom and / or feeder head. In this case, it can be understood that the boom and feeder head can be physically constructed from the feeder tube, and the functional differences between the two system parts are defined by the size of the components and how they are driven, and therefore their reactions to articulation are also different. For example, the tube section in the boom may be several meters long and articulate using hydraulic cylinders, while the tube section in the feeder head may be less than a meter in length and use smaller cylinders, rotary actuators, or linear actuators, or a choice of electronic or pneumatic actuators. In this case, the size and weight of the pipe section in the feeder head is reduced, allowing the use of smaller, lighter, and faster actuators, thereby improving the response speed and thus having a faster dynamic response than the boom.

[0114] The system generally includes a hopper configured to receive the building material and a pump configured to pump the building material from the hopper through a pipeline. Typical pumps used to pump cement are intermittent, which puts stress on the boom and causes large oscillations in the boom, which in turn adds additional stress to the operation of the feed head.

[0115] Thus, in an example, the above system can be used in conjunction with a continuous flow pump. In this example, the pump includes two pump cylinders, each having an associated swing valve, the position of which determines whether the pump cylinder is filled with material or dispensed. The pump includes a controller that partially empties one cylinder while the other is filled, and that increases the delivery rate of the other cylinder while reducing the delivery rate of one cylinder, thereby switching the delivery between the two cylinders to maintain the overall delivery rate.

[0116] More specifically, the pump includes a first cylinder including a first piston driven by a first actuator, the first cylinder being filled with building materials when the first piston is retracted from the first cylinder and conveying the building materials when the first piston is extended into the first cylinder, and a second cylinder equipped with a second piston driven by a second actuator, the second cylinder being filled with building materials when the second piston is retracted from the second cylinder and conveying the building materials when the second piston is extended into the second cylinder. The pump also includes a first swing valve and a second swing valve, the first swing valve connecting the first cylinder to the conveying pipe in a conveying position and allowing the building materials to enter the first cylinder in a filling position, and a second swing valve connecting the second cylinder to the conveying pipe in a conveying position and allowing the building materials to enter the second cylinder in a filling position.

[0117] In operation, the controller delivers building material by partially emptying one cylinder while filling the other, and shifts delivery between the two cylinders by decreasing the delivery rate of one cylinder while increasing the delivery rate of the other to maintain an overall delivery rate.

[0118] More specifically: in an initial step, the controller places the first swing valve in a filling position and retracts the first piston to fill the first cylinder, and then places the first swing valve in a delivery position and begins to extend the first piston to begin delivering building material from the first cylinder.

[0119] Then, in a first step, the controller continues to extend the first piston, thereby continuing to deliver building material from the first cylinder, and places the second swing valve in the fill position, retracting the second piston, to fill the second cylinder.

[0120] In the second step, once the second cylinder is full of building materials, the controller reduces the rate of extending the first piston to transport the remaining building materials in the first cylinder, and simultaneously places the second swing valve in the transport position to increase the rate of extending the second piston to transport the building materials from the second cylinder.

[0121] In a third step, once the first cylinder is empty, the controller places the first swing valve in the fill position and retracts the first piston to fill the first cylinder and continues to extend the second piston to continue delivering building material from the second cylinder.

[0122] In the fourth step, once the first cylinder is full of building materials, the controller places the first swing valve in the delivery position and begins to increase the rate of extending the first piston to deliver the building materials from the first cylinder, while decreasing the rate of extending the second piston to deliver the remaining building materials in the second cylinder.

[0123] Then repeat steps 1 to 4 as needed.

[0124] In one example, a pump cylinder includes a first sensor for measuring the position of a first piston and a second sensor for measuring the position of a second piston. Although the sensor can directly measure the piston position, it is more common to measure the piston position indirectly by measuring the actuator position, which is a surrogate for the piston position. A controller can control the first actuator and the second actuator based on the signals from the first sensor and the second sensor, which can be used to ensure accurate pump control.

[0125] In addition, the pumping device described above can also be used independently, specifically, it is suitable for any scene that requires pumping viscous fluid, especially continuous pumping. Therefore, its use in the building system described above does not limit the present invention.

[0126] Some specific applications and usage scenarios will now be described in more detail.

[0127] Applicants have developed a block laying robot comprising a long telescopic folding arm that is capable of rotating about the base of a mobile truck. A block laying and adhesive application head is mounted at the distal end of the arm. The end effector of the head (e.g., a fixture that places the blocks) is capable of being dynamically stabilized by the applicant's proprietary dynamic stabilization system (DST), which is described in previous publications, including US8166727, WO2009 / 026641, WO2009 / 026642, WO2018 / 009981, WO2018 / 009986 and WO2019 / 014701, the relevant contents of which are hereby incorporated herein by cross-reference.

[0128] DST is a method and system for stabilizing a robot end effector in real time by performing dynamic compensation to correct position errors of the end effector due to dynamic forces acting on the robot or its support. The system uses at least one robot that has a dynamic response faster than the dynamic input being compensated. In one non-limiting form, the DST system includes a first robot with a slower dynamic response for coarse positioning of the end effector, and a second robot coupled to the first robot, the end effector being mounted on the second robot, wherein the second robot has a fast dynamic response for precise positioning of the end effector. Thus, some large and relatively light and flexible structure can be used, on which a fast and accurate fine positioning mechanism is set, which can be precisely controlled in real time, thereby allowing precise and fast movement of the end effector relative to the environment.

[0129] Embodiments of DST-enabled long-arm machines for construction 3D printing, concrete pumping and delivery, and material operations (e.g., screeding) are disclosed herein. These machines enable dynamic stabilization (i.e., continuous path DST) of the end effector (e.g., delivery nozzle, screed head) as the arm traverses the work area.

[0130] In the following drawings, like reference numerals refer to like features, albeit with a prefix corresponding to the corresponding figure number. For example, the nozzle is indicated as 113 in FIG. Figure 3 It is represented as 313 in Chinese.

[0131] The following Figure 3 An example of a concrete pump is shown, comprising a vehicle 341 having a delivery head 310 attached to the end of a boom 342, replacing the normal hanging hose used in conventional concrete delivery devices.

[0132] The articulated feed head 310 has three rotating joints A, B, C, which are arranged in an articulated member 312 supporting a nozzle 313, which supports the nozzle 313 for delivering the building material M. The member 312 can be part of a robotic arm or other manipulable structure supporting a flexible feed pipe and / or an articulated pipe section. Alternatively, the member 312 can be made of the articulated pipe section itself. In any case, the pipe can deliver the building material to the nozzle 313.

[0133] The first pitch joint A rotates in the boom plane about a horizontal axis parallel to the boom articulated joint with a horizontal axis. Joint B provides rolling motion. Joint C provides a second tilt axis. By combining the motions of A, B, C, the nozzle tip 313 can move in three linear orthogonal dimensions. For concrete delivery, the angle of the nozzle is not important. Typical dimensions of the two links are about 500 mm long, the angular motion on B and C is about + / -15 degrees, and the linear motion at the nozzle is about 500×Cos15°=+ / -130 mm.

[0134] Joint ABC is automatically moved by the controller using suitable actuators (not shown) such as servo motors, etc. to stabilize the motion of the end of the nozzle 313 or to keep the nozzle 313 in a certain position or path at a desired feed rate, or to keep it on a desired curved or flat surface. The motion can be sensed by a tracking system, laser plane and line sensors or inertial measurement or by a combination of sensors. As examples of sensing systems, magnetic or capacitive sensors can detect the distance and direction to the rebar and keep the nozzle at a set height above the rebar and follow the direction of the rebar. The boom has slow dynamic response and a large range of movement, while axis ABC provides fast dynamic response in a small range.

[0135] Other sensing and guidance scenarios include: a) Maintaining constant altitude by sensing a rotating laser plane via a PSD. b) Following a teach wire or rope similar to a curb machine guidance system. c) Following a laser line. d) Tracking a trajectory by measuring DGPS (differential GPS) signals along with fine motion measured by an IMU. e) Machine vision. f) Ultrasonic distance sensors for maintaining altitude above the ground. g) Laser tracker or total station optical measurements.

[0136] For concrete pouring, the concrete needs to be leveled first to get a flat surface. Figure 4A feed head 410 is shown which includes additional joints and a leveling rod 451 which is supported by an articulated member 412 via a linear actuator 452, an articulated bracket 453 and a rotatable mount 454. The first joint D allows the leveling mechanism to rotate about the delivery nozzle so that it is in a trailing position relative to the delivery nozzle and the arm motion. Joints E, F and G provide three-axis wrist motion to keep the leveling arm horizontal while keeping the sliding axis H vertical. Axis H allows the height of the leveling rod to be adjusted. Axis J provides rotation about a vertical axis and axis K provides horizontal leveling motion and allows the leveling rod to sweep into corners and around obstacles such as pipes, rebar and columns.

[0137] For 3D printing, nozzle orientation can be important. Figure 5 Shown with Figure 3 Similar to the articulated feed head 510 , attached to the articulated member 512 is an additional member 514 having axes D, E, F providing wrist directional movement and ducting material to a trowel nozzle 513 rotating about axis G.

[0138] Measurement, stabilization and control allow the long arm to accurately deliver and level or trowel the material. The above example uses a large pipe diameter, compared to the use of a hose, which allows the use of high flow rates and large aggregates. It is well known that high pressure allows long distance pumping. Standard concrete pump pipes and fittings are easy to clean and have high reliability.

[0139] 3D printing is an inherently three-dimensional task, not a six-dimensional task like building blocks. Therefore, the printing nozzle only needs to be positioned in three dimensions (xyz), and its orientation only needs to be kept within about 10 degrees of vertical, and its yaw angle is not important. If the position of the nozzle tip can be measured, then only a three-dimensional tracking system can be used, and a six-dimensional tracking system is not required.

[0140] When pumping concrete and cement-based materials in 3D printing, rubber hoses should be avoided (abrasion, hose elongation, large bending radii required for high pressures and pulsation of material flow) and steel tubes are preferred. This is beneficial in avoiding linear motion axes and using articulated or swivel joints (bending joints).

[0141] Embodiments of the present disclosure relate to the concept of a dynamically stabilized 3D printing nozzle that can be mounted to the end of an arm to provide a nozzle that is precise in 3D space.

[0142] Figure 6A 3D printing nozzle 613 is shown which may be optionally mounted on the paving fixture of the robotic arm 612 of the paving head 610 of the Hadrian X machine, as described in previous publications including US8166727, WO2009 / 026641, WO2009 / 026642, WO2018 / 009981, WO2018 / 009986 and WO2019 / 014701 and US20210379775. This may serve as a low cost demonstration for use with existing Hadrian X equipment. It may be used to level uneven slabs or foundations, either the entire slab or just where blocks are to be laid. It may also be used for 3D printing in conjunction with automated block laying, for example, allowing the end effector 612.1 of the robotic arm 612 to be used to lay blocks, followed by grabbing the nozzle to apply mortar to the block layer.

[0143] Figure 7 A variation of this concept is shown where a 3D printing and mortar application nozzle 713 is permanently mounted on a laying jaw 712.1 of a robotic arm 712 of a Hadrian X block laying machine, and a conduit 715 (such as a rubber hose or articulated steel pipe) is used to deliver building material (such as mortar) to the nozzle 713. This can be used to apply mortar to both the bedding (horizontal) and vertical joints (vertical) during the block laying process.

[0144] Figure 8 A replacement head 810 is shown for replacing the robotic arm of a HadrianX block laying machine. In this example, the head 810 includes a bracket 812.1 pivotally mounted on an arm 842 via a horizontal axis, and a linear actuator arm 812.2 is rotatably mounted thereon about an orthogonal axis, thereby providing three-axis stabilized motion. The system can utilize a triple tracker tracking arrangement of the type described in US20210379775, the contents of which are incorporated herein by cross-reference. Specifically, the triple tracker arrangement includes three tracker targets 822 mounted on the arm 842 of the block laying machine, which can be detected by a laser tracker.

[0145] This form of apparatus includes a tracking base disposed in an environment, the tracking base including a tracking head support and at least three tracking heads mounted to the tracking head support. Each tracking head includes a radiation source for transmitting a radiation beam to a respective target, a base sensor for sensing reflected radiation, at least one tracking head actuator for controlling the orientation of the tracking head, and at least one tracking head angle sensor for monitoring the orientation of the tracking head. The target system includes at least three targets 822 mounted to the boom, each target including a reflector for reflecting a radiation beam to the base sensor of the respective tracking head. In this arrangement, the control system causes each tracking head to track a respective target as it moves throughout the environment, at least in part using signals from each base sensor and at least one sensor to determine the position of each target relative to the respective tracking head. The control system then uses the at least partially determined position of each target to determine the orientation of the target system, and uses at least in part the position and orientation of the target system to determine the position and orientation of the object.

[0146] Fig. 9 An arrangement similar to that described above is shown, where a feed head 910 comprises a support 912.1 pivotally mounted to an arm 942 about a horizontal axis, and a linear actuator arm 912.2 rotatably mounted thereto about an orthogonal axis, thereby providing three axes of stable motion. In this example, a simplified single tracker arrangement is used, with the tracker mounted on a retro-reflector 922 on the nozzle 913 and / or the actuator arm 912.2. The retro-reflector can be rotated about the nozzle to keep the tracker's line of sight consistent.

[0147] Fig.10 The layout of a 3D printer is shown, including a vehicle 1041 with a concrete pump 1061 and a hopper 1062, a boom 1042 extending from the vehicle and supporting a feed head 1010. In use, material is supplied from a silo 1063 or other delivery mechanism into the hopper 1062. From the hopper 1062, the material is provided to the pump 1061, where it is pumped to the feed head 1010 through a feed pipe forming the boom. This is similar to a concrete pump boom, for example made of Putzmeister or Schwing concrete.

[0148] Fig.11 Shown is a boom 1042 mounted on a vehicle 1041 and a hopper trailer 1164 containing 3D printing material.

[0149] It should be understood that a concrete pump type boom can be used in these configurations, although the boom end of a conventional concrete pump type boom is not dynamically stable. The addition of a feed head incorporating the type of DST (Dynamic Stabilization System) described above allows for precise 3D printing. 3D printing materials have lower flow rates than concrete and require higher pressures (printing materials and mortar have less slump than pumped concrete), and the boom is CNC controlled, so a standard concrete pump will need to be adapted to the task. Ideally, a custom machine would feature a lighter boom and smaller pipes (e.g. 40mm diameter instead of 100mm diameter).

[0150] Fig.12 A system is shown comprising an arm 1242 and a feed head 1210 having two articulated members 1212, such as articulated feed tube sections, supporting a nozzle 1213 and having articulation about axes A1, A2 and B1. This arrangement enables three-axis motion at the nozzle tip through all revolute (articulated) joints (pitch-pitch-roll or PPR joint sequence).

[0151] Fig.13 A system comprising an arm 1342 and a feed head 1310 is shown, which has a single articulated member 1312 for supporting a nozzle 1313 and having articulated joints on axes A1, A2 and B1. This arrangement achieves a similar Fig.12 The three-axis motion shown, but with a different joint order (pitch-roll-pitch or PRP), achieves the required three-axis motion of the nozzle tip through all rotational (articulated) joints.

[0152] Fig.12 and Fig.13 The concept of the robot or arrangement in is that the joints (A1, A2, B1) move the articulated member 1212 to move the end of the nozzle 1313. Although this movement will change the direction of the nozzle slightly, it is insignificant for the small DST correction movements required for 3D printing applications. Low response rate DST will be applied to the arm and high response rate DST will be applied to the nozzle robot.

[0153] A further embodiment of a feed head for a concrete pump or a large robot arm is Figures 14 to 22 Shown in.

[0154] Fig.14 A three-axis fine manipulator is shown on the end of a concrete pump arm 1442, which includes three articulated members 1412, such as pipe segments, or arms supporting pipe segments, or separate flexible pipes (see also Fig.16). The manipulator rotates in a gimbaled manner about the A and B axes. An optional Z-axis telescopic slide is available. The A, B, and Z axes will be hydraulically servo-driven or electric servo-driven to stabilize the tool center point (TCP). Stability can be achieved by inertial measurement to limit the acceleration of the TCP. Stability can be achieved by three-axis measurement at the end of the boom, for example by a laser tracker, ATS (Automatic TotalStation), theodolite, GPS, etc. The orientation of the feed tube is not important as long as it is roughly vertical and at a reasonable height. In most cases, the Z axis is not required.

[0155] In another optional mode of operation, the A and B axes may not be stabilized, but may be controlled individually to allow precise positioning of the nozzle without moving the boom 1442. This may be used to replace the manual process currently performed by a person holding a hanging hose. Alternatively, the A and B axes may be controlled in a cyclic or repetitive motion, for example, the boom moves along a linear path and the A and B axes may move the nozzle left and right to distribute concrete over a wider area. Or, for example, as the boom moves the nozzle upward, the A and B axes may direct the nozzle toward rebar and formwork around the edge of a column.

[0156] It should be noted that in the example above, the nozzle is shown pointing vertically downwards. However, the nozzle can be pointed more horizontally and used to spray materials, such as shotcrete, enabling the delivery of building materials onto vertical or inclined surfaces.

[0157] By combining the TCP control of the boom 1442 with the TCP control of the A, B, and Z axes, the nozzle 1413 can be programmed to automatically place concrete on a slab or in a formwork, spray shotcrete, or place 3D printed building materials along a work path.

[0158] Fig.15A An apparatus is shown incorporating linear actuators 1516.1, 1516.2, 1516.3, such as electronic, pneumatic or hydraulic actuators for providing articulation about the A, B and Z axes. In addition, the apparatus includes a "kerbstone" type forming trowel 1571, which is mounted at the end of the nozzle and rotated about axis P using a rotary actuator 1516.4. This will allow the arm to lay kerbs, or build walls by stacking layers of kerbs. The kerb head with an internal reciprocating plunger 1571.1 compacts the concrete to completely fill the trowel form and create a high quality void-free product. As shown Fig. 15BThe use of a linear actuator 1572.1 to mount the cutter 1572 to the nozzle and / or feed head is shown, which allows the cutter 1572 to be positioned at will to start the curb or wall at a specific location by holding the feed head stationary while the concrete is compacted using a biasing mechanism such as a plunger 1571.1. It also allows the construction of the curb or wall to be completed at a designated completion location by cutting the wall or curb at that designated completion location and then hauling away the excess.

[0159] Fig.15A It also shows how to use cylinders (either hydraulic or electric) to move the A, B, and Z axes. Note that the A and B axes should have a limited range of motion to limit the change in the curb head angle. The A and B axes only need to move enough to correct for the accuracy of the boom and the amount of lateral bounce.

[0160] Fig.16 An arrangement is shown including a rotary actuator, such as an electronic, pneumatic or hydraulic actuator for providing articulation about the A, B and Z axes. Specifically, in this example, a ring gear or hollow reducer 1616.11, 1616.21 driven by a hydraulic rotary motor or electric servomotor 1616.12, 1616.22 can be used to move the A and B axes, while a rack 1616.31 and pinion 1616.32 can move the Z axis. It also shows material M being conveyed synchronously with the rebar 1601.

[0161] It should be noted that in Figures 12 to 16 In the above example, the feed head structure is formed by a feed pipe, with a swivel joint in the pipe to achieve rotational articulation. In this example, the pipe can use the normal rotary seals used on folding concrete pump arms and have additional bearings to support the structure in a rigid manner.

[0162] Fig.17 Shows something like Fig.16 1712.3 is a similar arrangement to that of the conventional conventional concrete mixer, but with the addition of a leveling member in the form of a leveling rod 1751 mounted to the nozzle 1713 by a bracket 1712.3. The leveling rod 1751 can be rotated about a substantially vertical axis C using a rotary actuator 1716.5 and slides on a horizontal axis W by a rack 1716.41 and a pinion 1716.42. The C and W axes enable the leveling rod to get into corners and to move side to side or sweep in an arcuate pattern to move, distribute and smooth concrete, thereby producing a smooth concrete Ms. Additionally, the bracket 1712.3 can be rotatably mounted to the nozzle 1713, allowing the leveling rod 1751 to follow the nozzle.

[0163] It is important to note that when leveling, it is expected that the A and B axes will be used to keep the C axis vertical. The C and W axes will move the concrete. The boom will remain essentially stationary or move on a slow, continuous programmed or commanded trajectory. The C and W axes can be programmed to have a virtual TCP at a point on the leveling bar and the motion can be programmed to keep the leveling bar TCP on the path. For example, one end of the leveling bar can be set up as a TCP and then the boom and leveling bar can be programmed so that the leveling bar TCP follows the edge of the plate along the formwork. Note that a laser or tight metal wire (chord) for example can be set up to provide a straight line reference and the leveling bar can be made to follow the laser line by sensing the metal wire from the laser line or electromagnetic proximity sensors via PSD sensors.

[0164] The boom can learn entire movements or the boundaries of a movement. For example, it can manually guide the boom around the edge of a slab, or to the corner of a polygon, then enter automatic mode to automatically fill a polygon or other set shape with concrete, and then switch to leveling mode to level, trowel and smooth the concrete.

[0165] The leveling bar can be replaced (via quick connect) with a "trowel", helicopter trowel, trowel or other tool.

[0166] Fig.18 Shows something like Fig.17 arrangement except that a chute 1752 is added which is connected to the actuator 1716.7 and can rotate about axis D to distribute the concrete. This allows the use of longer screed bars and the concrete to be placed over a wider area with each "sweep" of the main boom. The chute can be manually controlled, programmed to follow the TCP, or programmed to oscillate or rotate. A typical movement is to program the boom and screed bar to a TCP trajectory to lay a concrete slab "diagonally" from a corner, while the chute oscillates to distribute the concrete over approximately half the width of the screed bar.

[0167] It is important to move the screed bar perpendicular to the W axis so that it is pushing directly against the concrete. This will allow the screed bar to work the concrete in a desired pattern, such as a figure 8, where it pushes concrete onto previously laid concrete and then levels it into the new area.

[0168] Fig.19 Shown with Fig.18 A similar arrangement except that the chute 1852 is replaced by a conduit 1953 and driven by a rotary drive or hollow reducer 1916.7.

[0169] Fig. 20 Shows something like Fig.18arrangement, although the sliding linear Z axis is replaced by a J-shaped articulated arm 2018 having rotary actuators 2018.1 and 2018.2 at either end to articulate about axes E and F. Changing the angle of axes E and F effectively changes the distance between the A axis and the nozzle (or TCP).

[0170] Fig.21 An arrangement of the feed head is shown which will correct for the main movements of the boom 2142, i.e. the up and down and "in-out" bounce of the boom, and will not correct for the sideways (boom rotation) movement. The articulated members 2112.1, 2112.2 (e.g., articulated tube members or arms supporting pipe sections or flexible pipes) and the nozzle 2113 pivot so that they effectively form a SCARA type robotic device that allows vertical and horizontal movement within the vertical plane of the boom. The nozzle end 2113 can pivot freely and be aligned by gravity, and can support the hose. This arrangement only requires two additional axes of motion, and is effective in providing precise control of the end of the pipe, but of course will not correct for the rotational direction movement of the boom.

[0171] Fig. 22 A 5-axis fine manipulator for integration onto the end of a concrete pump arm 2242 is shown, comprising five articulated members 2212.1, 2212.2, 2212.3, 2212.4, 2212.5, the latter of which may incorporate a delivery nozzle. This allows correction and compensation of the position and orientation of the delivery nozzle. Note that an additional sixth axis (not shown) may be added to orient, for example, a spatula or leveling device. In the arrangement shown, the delivery nozzle is directed substantially horizontally in a shotcrete spraying attitude. For example, the device may spray shotcrete onto a wall or wall formwork or reinforcement, and then level and trowel on the wall or 3D formed shell (e.g., a dome). This would also allow large-scale and free-form 3D printing. In another arrangement, the delivery nozzle may be oriented in a vertical attitude, which is a typical orientation for casting slabs. It should be understood that other items previously described (chutes, pipes, leveling bars, etc.) may also be added to this arrangement.

[0172] Another aspect of the invention relates to a pump for pumping concrete.

[0173] Prior art uses double piston pumps to pump concrete, and now we will refer to Fig.23A and 23BDescribe an example. Typically, such a pump has hydraulic cylinders 2381, 2382, which push corresponding pistons in cylinders 2381, 2382, respectively, and these cylinders 2381, 2382 are selectively connected to a feed pipe 2386 through a swing valve 2385. Concrete enters the pump cylinder, is forced out by the pistons pushed by hydraulic cylinders 2383, 2384, and the swing valve 2385 is rotated to switch from one cylinder to another, so that concrete is pumped from one cylinder while the other cylinder is filled with concrete. In this way, the pistons corresponding to the cylinders 2381, 2382 alternately pump and fill concrete.

[0174] The intermittent nature of the flow creates large varying forces and intermittent flow of concrete in the feed pipe, which causes the boom to bounce. Bounces can fatigue the boom structure, dynamic pressure fluctuations can fatigue the pipe, and a bouncing boom can cause inconsistent concrete delivery. Flow variations make it difficult or even impossible to deliver concrete to the intended path. Flow variations also make it difficult to deliver concrete evenly to the slab, requiring extensive manual movement of concrete (via rakes, screeds, shovels, etc.) to deliver concrete to the correct location.

[0175] like Fig.24 As shown, the improved pump device is intended to achieve uniform, continuous and variable concrete flow and delivery. It replaces the single swing valve with two swing valves 2485.1, 2485.2, one for each pump cylinder 2481, 2482. The pump piston is controlled by a servo hydraulic cylinder or hydraulic cylinders 2483, 2484 so that the total flow remains constant. To achieve this goal, the filling speed of the pump cylinder being filled is faster than the delivery speed of the delivery cylinder. At the end of the piston stroke of the first cylinder 2481, the second swing valve 2485.2 moves to the delivery position and starts the piston stroke of the second cylinder 2482 so that when the first piston slows down, the second piston accelerates, just to maintain a constant flow. When the second piston stroke is close to the end, the first piston stroke accelerates. The position of the hydraulic piston is measured by a linear encoder, such as a Temposonics cylinder rod encoder or by an encoder integrated into the cylinder rod (such as a Parker magnetic rod encoder). Preferably, the position of the cylinder, the pressure of the delivered concrete and the required flow are used in a feedback loop to control the speed and position of the hydraulic cylinder.

[0176] Two, three or more pump cylinders and swing valves can be used to accommodate a variety of materials. For example, if a certain material does not fill the pump cylinders fast enough, more pump cylinders can be used.

[0177] The pump is suitable for conveying 3D printing materials that require high pressure and continuous flow.

[0178] The application of this pump is to control the delivery of concrete pump arms along the TCP to deliver concrete evenly to the slab or mould or formwork.

[0179] The pump can be used to transport 3D printing materials over long distances.

[0180] Piston pumps have a longer life than peristaltic or screw pumps, are capable of higher pressures, and have better wear resistance than gear pumps.

[0181] An example of a processing machine for processing building materials will now be described.

[0182] refer to Figures 25A to 25E , showing a DST assisted concrete leveling pole and helicopter trowel that can work in conjunction with a concrete boom pump.

[0183] In this example, a concrete conveyor 2590 is provided, which may be similar to those described above, or may be an existing concrete delivery system including a truck mounted or tower crane column mounted high rise concrete boom pump, depending on the application.

[0184] In this example, the working machine 2500 includes a base 2541, which may be a vehicle or a high-rise tower crane column, with a boom 2542 extending therefrom. The boom 2542 includes an articulated working head 2510 of a similar form to the feeder head described above. The working machine is used in conjunction with a tracking system 2520, similar to the systems described above, which can be used to track the movement of the boom, the working head, or a working component attached to the working head.

[0185] like Fig.25C As shown, in one example, the work head includes a leveling rod 2551 mounted on an articulated member 2512, the articulated member 2512 including a linear actuator 2512.2 to allow the work piece to be raised and lowered. The articulated member 2512 is attached to the arm via a swivel joint 2512.1, allowing the articulated member 2512 and thus the leveling rod 2551 to be changed in orientation.

[0186] This arrangement is primarily used for concrete leveling, however, the tool head can be used with leveling and straight-lift trowels (or lighter trowels) 2572 (e.g. Fig.25E as shown) or steel bar tie rod head 2571 (as shown Fig.25D Other suitable working parts may include concrete grinding and polishing heads, painting, pressure washing or sandblasting heads. The leveling bar can act as a "rough rake" to spread concrete and then level it.

[0187] The workhead does not necessarily need to be corrected for all 6DOF with DST, but this does not mean it is not required in all cases and may be used in some cases depending on the nature of the work being performed. A semi-automatic type of operation works very well here, where the XY plane position of the boom 2542 is controlled by the operator with a joystick (the control system will do the kinematic transformation and calculate the required boom rotation, lift, luffing and extension angles), while the angle of the screed bar is controlled by a joystick or lever. The roll, pitch and Z axis movement of the screed bar working part (and the Z axis of the boom) will be automatically controlled by the DST. The operator can raise the working part in the Z axis by manual control to retrieve or handle large piles of concrete, but there will be a "virtual ground level" that the operator cannot go below (without pressing some kind of override button). For troweling work that requires multiple passes, a "teach mode" can be set up, in which the boom learns the movement, and then the operator can control the "feed speed" of the boom with the left joystick, and the right joystick controls the rotation speed of the trowel (the trowel speed needs to change as the concrete cures).

[0188] The boom can be very light and simple in structure, similar to a Hiab crane, and can be assembled from steel components. The boom can be mounted to a concrete pump truck as an independent second boom or retrofitted to an existing truck type boom, such as a Hiab, Effer. The boom can also be mounted on a tower crane column for use with a high-rise concrete boom pump.

[0189] Additional telescopic stages can be added to meet any extension requirements. Typical concrete pump booms have an extension range of 20m to 60m. For example, a 32m long extension boom is available as a mid-range option, which is much more practical than a 5m extension "self-leveler" (Lichine Screed saver Boss or Dragon Screed).

[0190] It will be appreciated that the articulated telescopic boom assembly can be used in conjunction with a concrete pump boom. A work head can also be added to the boom of an excavator as an attachment.

[0191] A LiDAR sensor on the head of the leveling pole can be used to provide safety presence sensing. The LiDAR will operate above the leveling pole height.

[0192] Figures 26A to 26C Further shown in FIG. 1 is a DST-enabled leveling head attached to the end of a long boom.

[0193] In this example, the working head 2610 is connected to the arm 2642, respectively. Fig.26A and Fig.26BIn this example, the leveling rod 2651 is connected to an articulated member 2612, which includes a linear actuator 2612.2 and is connected to the arm through a rotating joint 2612.1, 2612.3 to allow movement in three degrees of freedom.

[0194] As an alternative to the interchangeable heads allowing the use of a leveler or helicopter trowel, a leveling bar including an attachable or deployable trowel may be provided, reference now being made to Fig.27A and 27B An example thereof is described.

[0195] exist Fig.27A In the example of , the leveling rod 2751 is rotatably mounted to the hinge member 2712 using a rotary servo motor 2712.4, thereby allowing the leveling rod to rotate. A spatula element is provided that can be connected to the leveling rod so that the leveling rod acts as a helicopter spatula when rotated. Fig.27B In the example of , the spatula elements are hingedly mounted to the leveling rod 2751 so that they can be folded into place and secured in place using the connecting rod 2753.

[0196] This avoids having to connect the power supply via the detachable connection of a separate helicopter spatula.

[0197] Usually, helicopter trowels are equipped with 4 trowels, so the 4 trowels are in a self-stabilizing state. If the head is stable, it is also possible to install two trowels or even one trowel. Only one trowel is needed to apply mud into corners or to apply it in a specific pattern, such as for surface shaping.

[0198] A texture brush, broom or roller (for surface texturing) or a grooved trowel can also be fitted to the trowel expansion joint.

[0199] A powder dispensing unit may be installed to dispense cement powder, hardeners, pigments, acids, paints, liquid membranes (e.g. moisture evaporation inhibitors, accelerators, films etc.) A roll material dispenser may also be installed, such as plastic sheeting for rain protection, under-slab plastic (i.e. used before concrete is spread), pond or dam lining plastic or concrete surface texture formwork such as "crazy paving" or "block paving" formwork.

[0200] Of course, other accessories can also be installed, such as grinding heads, drill bits, etc.

[0201] Regarding head position measurement, in order to reduce the cost of laser trackers, e.g. Fig.28 As shown, a standard rotary laser level and machine position sensitive detector (PSD) can also be used.

[0202] In this example, the leveling rod 2851 is rotatably mounted to the hinge member 2812 using a rotary servo motor 2812.4, allowing the leveling rod 2851 to rotate. Three PSDs 2882 are arranged to measure three points on the plane. In order to maintain a good line of sight when the boom rotates above the construction site, the three PSDs are mounted on a frame that rotates around the Z axis. The PSDs only obtain signals at the rotation frequency of the rotating laser 2881, which is not fast enough for dynamic compensation, so a Z-axis accelerometer is added and arranged at each PSD position. The XY position of the leveling rod is not important because its task is to establish a flat plate.

[0203] The bar extensions are long and a long enough hydraulic ram would be heavy. So a chain / tension or rope system would be needed to "speed up the motion". It would probably be easier and better to servo drive it through a rack. Putting the rack on top of the club means the structure of the club is well supported, with little play on the telescoping sidewalls, and continuous support on the bottom of the inner club. Fig.29 An example of a rod extension arrangement using Ultra High Mechanical Polyethylene (UHMPE) is shown.

[0204] In this example, the arm elements 2942.1, 2942.2 are telescopic, with a rack 2942.4 mounted on the inner element 2942.2, and the outer arm element 2942.1 including a drive motor 2942.3 that drives a pinion meshing with the rack, thereby achieving retraction and extension of the arm element 2942.2.

[0205] In this specification and the claims that follow, unless the context requires otherwise, the word "comprise" and variations thereof, such as "includes" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers. As used herein, the term "about" means ±20%, unless otherwise specified.

[0206] It will be appreciated by those skilled in the art that various changes and modifications will occur. All of these changes and modifications that are obvious to those skilled in the art should be included within the broad spirit and scope of the present invention described above.

Claims

1. A robotic construction system for constructing a building, characterized in that: The construction system includes: a) Base; b) an arm extending from the base; c) an articulated feed head connected adjacent an end of the boom, the feed head including a nozzle configured to deliver building material; and d) a controller configured to control movement of the boom and the feed head to move the nozzle and deliver the building material, wherein the boom has a slower dynamic response over a larger distance and the feed head provides a faster dynamic response over a smaller distance.

2. The system according to claim 1, characterized in that The controller is configured to control the feed head to dynamically stabilize the nozzle to correct for unintentional movement of the boom end.

3. The system according to claim 1 or 2, characterized in that: The controller is configured to control the boom and the feed head to control movement of the nozzle during delivery of the building material.

4. The system according to any one of claims 1 to 3, characterized in that: The controller is configured to control the boom and the delivery head to deliver the building materials along a desired delivery path.

5. The system according to claim 4, characterized in that When conveying building materials, the controller is configured to: a) controlling the boom to move the boom end to provide a coarse guided movement of the nozzle relative to the delivery path; and b) Controlling the feed head to move the nozzle, thereby providing precise positioning of the nozzle as it moves relative to the delivery path.

6. The system according to claim 4 or claim 5, characterized in that: The controller is configured to control the boom and the feed head to move the nozzle relative to at least a portion of the delivery path as the building material is continuously delivered.

7. The system according to any one of claims 1 to 6, characterized in that The feed head is articulated on two axes, moving the nozzle with two degrees of freedom, thus allowing the nozzle to be moved in two orthogonal spatial directions.

8. The system according to claim 7, characterized in that The two orthogonal spatial directions are one of the following: a) Horizontal spatial direction to correct for longitudinal and lateral movements of the boom end; b) one horizontal and one vertical to correct for longitudinal and vertical movement of the boom end; and c) One horizontal and one vertical to correct for lateral and vertical movement of the boom end.

9. The system according to any one of claims 1 to 8, characterized in that The feed head is articulated on three axes to move the nozzle with three degrees of freedom, thus allowing the nozzle to be moved in orthogonal spatial directions.

10. The system according to claim 9, characterized in that The movement of the nozzle in orthogonal spatial directions is used to correct the longitudinal, transverse and vertical movements of the boom end.

11. The system according to any one of claims 1 to 10, characterized in that The feed head is articulated on the shaft to provide one of the following functions: a) pitch, roll, and pitch motion; b) pitch, elevation and roll motion; and c) Pitch, roll and slide motions.

12. The system according to any one of claims 7 to 11, characterized in that The feed head is further hinged on another axis to adjust the spacing of the nozzles.

13. The system according to claim 12, characterized in that The feed head is hinged on another axis to adjust the direction of the nozzle.

14. The system according to any one of claims 1 to 13, characterized in that The feed head is articulated using at least one of the following: a) Rotary actuator; b) Linear actuator; c) Hydraulic motor; d) electric motor; e) Hydraulic cylinder; f) Electric punch; g) hydraulic servo systems; and h) Electric servo system.

15. The system according to any one of claims 1 to 14, characterized in that: The system uses one of the following methods: a) the nozzles are arranged substantially vertically to deliver the building material downwardly onto the surface; and b) The nozzles are arranged substantially horizontally to deliver the building material laterally onto the surface.

16. The system according to any one of claims 1 to 15, characterized in that The feeding head comprises a robot arm and an end effector, wherein the nozzle is supported by the end effector.

17. The system according to any one of claims 1 to 16, characterized in that: The feeding head includes working parts for operating the conveyed building materials.

18. The system according to claim 17, characterized in that A working part includes one of the following: a) Leveling the parts; b) spatula; c) Templates; d) Mould; e) a biasing member configured to urge the working material; f) cutting tools; g) Grinding head; h) Polishing head; i) Washer head; j) sandblasting heads; and k) Cutting machine.

19. The system according to claim 17 or 18, characterized in that The feed head is articulated to perform at least one of the following operations: a) Independently move the working parts and nozzles; b) moving the working part relative to the nozzle; c) Allowing the working part to rotate around the nozzle; d) controlling the height of the working part relative to the nozzle; and e) Control the direction of the working parts.

20. The system according to any one of claims 17 to 19, characterized in that The feed head articulates about three axes to maintain the working part in a fixed orientation and provides further articulation to allow adjustment of the height and / or position of the working part.

21. The system according to any one of claims 17 to 20, characterized in that The feed head is articulated to allow rotation and horizontal movement of the working part.

22. The system according to any one of claims 1 to 21, characterized in that The system includes a boom actuator configured to move the boom.

23. The system according to claim 22, characterized in that The boom actuator is configured to implement at least one of the following functions: a) Rotating arm; b) Extend or retract the boom; c) deploying the boom; and d) Raise or lower the boom.

24. The system according to any one of claims 1 to 23, characterized in that The system includes a tracking system configured to measure the position and / or movement of at least one of: a) Feeding head; b) boom end; c) boom; as well as d) nozzle; And the controller is configured to control the feed head according to the signal from the tracking system.

25. The system according to claim 24, characterized in that The tracking system shall include at least one of the following: a) Laser guide; b) physical guides and corresponding guide sensors; c) Positioning sensor; d) GPS sensor; e) Mobile sensors; f) Inertial measurement unit; g) Machine vision system; h) Laser tracker; i) LiDAR; j) radar; k) distance measuring sensors; and l) Ultrasonic ranging sensor.

26. A system according to claim 24 or claim 25, characterised in that The tracking system includes: a) three retroreflectors mounted near the end of the boom; and b) A corresponding laser tracker, wherein the tracking system is configured to measure the position and orientation of the boom end based on rays reflected from the retroreflector.

27. The system according to claim 24 or 25, characterized in that The tracking system includes: a) a retroreflector movably mounted on an articulated head adjacent the nozzle; and b) Laser trackers, where a tracking system is configured to measure the position and orientation of the nozzle based on rays reflected from a retroreflector.

28. The system according to claim 24 or 25, characterized in that The tracking system includes: a) laser guides located in the environment; and b) A sensor mounted on at least one of the arm and the feed head, the sensor being configured to detect deviation from the laser guide.

29. The system according to claim 28, characterized in that Laser guidance defines at least one of the following: a) height plane; and b) Transmission path.

30. The system according to any one of claims 1 to 29, characterized in that The system includes a feed tube configured to transport building material from a base along a boom to a nozzle.

31. The system according to claim 30, characterized in that The feed pipe consists of an articulated steel pipe.

32. The system according to claim 30 or 31, characterized in that At least one of the feeding pipe and the arm is formed by hinged connection of the feeding pipe.

33. The system according to any one of claims 30 to 32, characterized in that The system includes a hopper configured to receive a building material and a pump configured to pump the building material from the hopper through a conduit.

34. The system according to claim 33, characterized in that The pump includes: a) Two pump cylinders; b) an associated swing valve on each pump cylinder, the position adjustment of which determines whether the pump cylinder is filling or discharging material; and c) a controller configured to deliver the building material by: i) partially emptying one pump cylinder while another pump cylinder is filling; and ii) reducing the delivery rate of one pump cylinder while increasing the delivery rate of the other pump cylinder, thereby maintaining the overall delivery rate when switching delivery between the two pump cylinders.

35. The system according to claim 34, characterized in that The pump includes: a) a first cylinder including a first piston driven by a first actuator, the first cylinder being configured to be filled with building material when the first piston is retracted from the first cylinder and to deliver the building material when the first piston is extended into the first cylinder; b) a second cylinder including a second piston driven by a second actuator, the second cylinder being configured to be filled with building material when the second piston is retracted from the second cylinder and to deliver the building material when the second piston is extended into the second cylinder; c) a first swing valve which, in the delivery position, connects the first cylinder to the feed pipe and, in the filling position, allows the building material to enter the first cylinder; d) a second swing valve, which connects the second cylinder to the feed pipe in the delivery position and allows the building material to enter the second cylinder in the filling position; e) a pump controller configured to control the first actuator and the second actuator and the first swing valve and the second swing valve to achieve: i) Partial emptying of one pump cylinder while the other pump cylinder is filling with conveyed building material; ii) Transitioning from one pump cylinder to another by decreasing the delivery rate of one pump cylinder while increasing the delivery rate of another pump cylinder, thereby maintaining the overall delivery rate.

36. The system according to claim 35, characterized in that The pump controller is configured for: a) Initial steps: i) positioning the first swing valve in a fill position and retracting the first piston to fill the first cylinder; ii) positioning the first swing valve in a delivery position and beginning to extend the first piston to begin delivering the building material from the first cylinder; b) In the first step: i) continuing to extend the first piston, thereby continuing to convey the building material from the first cylinder; ii) positioning the second swing valve in the fill position and retracting the second piston, thereby filling the second cylinder; c) In the second step, once the second cylinder is filled with building material: i) reducing the rate of extension of the first piston, thereby conveying the remaining building material from the first cylinder; ii) positioning the second swing valve in the delivery position and beginning to extend the second piston at an increasing rate to begin delivering the building material from the second cylinder; d) In the third step, once the first cylinder is empty: i) positioning the first swing valve in a fill position and retracting the first piston, thereby filling the second cylinder; ii) continuing to extend the second piston, thereby continuing to deliver the building material from the second cylinder; e) In the fourth step, once the first cylinder is filled with building material: i) positioning the first swing valve in a delivery position and beginning to extend the first piston at an increasing rate to begin delivering building material from the first cylinder; ii) reducing the rate of extension of the second piston, thereby delivering the remaining building material from the second cylinder; f. Repeat steps 1 to 4 as needed.

37. A system according to any one of claims 1 to 36, characterized in that Building materials include at least one of the following: a) Viscous fluid; b) cement-based materials; c) concrete; d) cement; e) mortar; f) Shotcrete; g) 3D printing materials; and h) Polymeric materials.

38. A system according to any one of claims 1 to 37, characterized in that The chassis is part of the vehicle.

39. A building material pump comprising: a) Two pump cylinders; b) an associated swing valve on each pump cylinder, the position adjustment of which determines whether the pump cylinder is filling or discharging material; and c) a controller configured to deliver the building material by: i) partially emptying one pump cylinder while another pump cylinder is filling; and ii) reducing the delivery rate of one pump cylinder while increasing the delivery rate of the other pump cylinder, thereby maintaining the overall delivery rate when switching delivery between the two pump cylinders.

40. The pump of claim 39, wherein the pump comprises: a) a first cylinder including a first piston driven by a first actuator, the first cylinder being configured to be filled with building material when the first piston is retracted from the first cylinder and to deliver the building material when the first piston is extended into the first cylinder; b) a second cylinder including a second piston driven by a second actuator, the second cylinder being configured to be filled with building material when the second piston is retracted from the second cylinder and to deliver the building material when the second piston is extended into the second cylinder; c) a first swing valve which, in the delivery position, connects the first cylinder to the feed pipe and, in the filling position, allows the building material to enter the first cylinder; d) a second swing valve, which connects the second cylinder to the feed pipe in the delivery position and allows the building material to enter the second cylinder in the filling position; e) a pump controller configured to control the first actuator and the second actuator and the first swing valve and the second swing valve to achieve: i) Partial emptying of one pump cylinder while the other pump cylinder is filling with conveyed building material; ii) Transitioning from one pump cylinder to another by decreasing the delivery rate of one pump cylinder while increasing the delivery rate of another pump cylinder, thereby maintaining the overall delivery rate.

41. The pump of claim 40, wherein the pump controller is configured to: a) Initial steps: i) positioning the first swing valve in a fill position and retracting the first piston to fill the first cylinder; ii) positioning the first swing valve in a delivery position and beginning to extend the first piston to begin delivering the building material from the first cylinder; b) In the first step: i) continuing to extend the first piston, thereby continuing to convey the building material from the first cylinder; ii) positioning the second swing valve in the fill position and retracting the second piston, thereby filling the second cylinder; c) In the second step, once the second cylinder is filled with building material: i) reducing the rate of extension of the first piston, thereby conveying the remaining building material from the first cylinder; ii) positioning the second swing valve in the delivery position and beginning to extend the second piston at an increasing rate to begin delivering the building material from the second cylinder; d) In the third step, once the first cylinder is empty: i) positioning the first swing valve in a fill position and retracting the first piston, thereby filling the second cylinder; ii) continuing to extend the second piston, thereby continuing to deliver the building material from the second cylinder; e) In the fourth step, once the first cylinder is filled with building material: i) positioning the first swing valve in a delivery position and beginning to extend the first piston at an increasing rate to begin delivering building material from the first cylinder; ii) reducing the rate of extension of the second piston, thereby delivering the remaining building material from the second cylinder; f. Repeat steps 1 to 4 as needed.

42. A pump according to claim 40 or 41, wherein the pump comprises: a) a first sensor configured to measure a position of a first piston; as well as b) A second sensor configured to measure a position of the second piston, wherein the controller may control the first actuator and the second actuator according to signals from the first sensor and the second sensor.

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