Building material processing

Abstract

A robotic construction system for building a building includes a base, a boom extending from the base, and an articulated work head mounted near an end of the boom. The work head includes a work component configured to process the building material, and a controller configured to control movement of the boom and the work head to move the work component and process the building material. Wherein the arm support has a slow dynamic response in a large distance, and the working head provides a fast dynamic response in a small distance.

Description

Technical Field

[0001] The present invention relates to a system for processing building materials and, in particular, to a machine for processing concrete and other similar materials using techniques such as screeding. 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 cementitious materials is a well-known technology. Typically, these extruders work on a gantry system or, if mounted on an articulated arm, the arm has a small travel area. Typically, the material is delivered via a rubber or flexible hose, which is usually arranged along a linear axis via a cable chain, or suspended from a mast. Rubber hoses are small in diameter, relatively heavy and expensive, and have limited pressure resistance and durability (relative to steel or metal pipes). The low pressure resistance and small diameter of the hoses limit the distance that the construction material can be pumped, restrict the rheology of the material and the size of aggregate that can be pumped. As a result, these materials are expensive compared to commercial concrete.

[0004] Concrete pumps typically have a large, articulated boom of 4 or 5 sections, in a Z-fold or roll-fold configuration. Concrete is conveyed along the boom via steel pipes that pass through the boom joints via swivel connections. Typically, the concrete is ultimately conveyed 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 movements 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 where it is needed.

[0005] There are machines available for processing delivered building materials. Examples include machines for leveling concrete and machines for molding concrete materials to give the material a specific surface finish. Typically, such machines are customized for each task, meaning that different equipment is required for leveling to polishing or grinding. Additionally, each type of machine is typically manually operated and needs to be located at the processing site of the building material. This poses a challenge for scenarios such as applications in high-rise buildings, as it may be necessary to transport the machine to the specific floor being constructed. Summary of the invention

[0006] Broadly speaking, one aspect of the present invention is directed to a robotic construction system for constructing a building, the construction system comprising: a base, a boom extending from the base, an articulated work head connected near the end of the boom, the work head comprising a working part configured for processing building materials, and a controller configured to control the movement of the boom and the work head to move the working part and thereby process the building materials, wherein the boom has a slower dynamic response over a larger distance and the work head provides a faster dynamic response over a smaller distance.

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

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

[0009] In one embodiment, the controller is configured to control the boom and the work head to process the building material along the work path.

[0010] In one embodiment, when processing building materials, the controller is configured to: control the boom to move the boom end to provide a rough guided movement of the working member; and control the working head to move the working member to achieve precise positioning of the working member.

[0011] In one embodiment, the controller is used to control the boom and the working head so that the boom and the working head move simultaneously.

[0012] In one embodiment, the working head is articulated on two axes to move the working part with two degrees of freedom, thereby allowing the working part to move 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 working head is articulated on three axes to move the working member with three degrees of freedom, thereby allowing the working member to move in orthogonal spatial directions.

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

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

[0017] In one embodiment, the working head is further articulated on another axis to adjust the pitch movement of the working part.

[0018] In one embodiment, the working head is articulated on another axis to adjust the orientation of the working part.

[0019] In one embodiment, the working 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 ram; a hydraulic servo system; and an electric servo system.

[0020] In one embodiment, the working head includes a robotic arm and an end effector, wherein the working part is supported by the end effector.

[0021] In one embodiment, the working component includes one of the following: a leveling component; a trowel; a template; a mold; a biasing member configured to push the processed material; a cutting tool; a grinding head; a polishing head; a washer head; a sandblasting head; and a cutter.

[0022] In one embodiment, the working head is articulated to at least one of: allow rotation of the working component; control the height of the working component; and control the direction of the working component.

[0023] In one embodiment, the working 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.

[0024] In one embodiment, the working head is articulated to allow for both rotational and horizontal movement of the working component.

[0025] In one embodiment, the system includes a boom actuator configured to move the boom.

[0026] 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.

[0027] In one embodiment, the system includes a tracking system configured to measure the position and / or motion of at least one of: a work head; a boom end; a boom; and a work part; and the controller is configured to control the work head based on signals from the tracking system.

[0028] 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.

[0029] 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.

[0030] In one embodiment, the tracking system includes: a retroreflector movably mounted on an articulated joint proximate to a workpiece; and a laser tracker, wherein the tracking system is configured to measure a position and orientation of the workpiece based on radiation reflected from the retroreflector.

[0031] 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 work head, the sensor being configured to detect deviations from the laser guide.

[0032] In one embodiment, the laser guide defines at least one of: a height plane and a working path.

[0033] In one embodiment, the system includes a nozzle configured to deliver building material.

[0034] In one embodiment, the working head is articulated to at least one of: independently move the working member and the nozzle; move the working member relative to the nozzle; allow the working member to rotate about the nozzle; control the height of the working member relative to the nozzle; and control the direction of the nozzle.

[0035] In one embodiment, the work head is articulated about three axes to allow the nozzle to be maintained in a fixed orientation, and further articulation is provided to allow the height and / or position of the nozzle to be adjusted.

[0036] In one embodiment, the work head is articulated to allow rotation and horizontal movement of the nozzle.

[0037] In one embodiment, the feed head is hinged on another additional axis to adjust the orientation of the nozzle. It should be understood that the broad forms of the invention and their respective features can be used in combination and / or independently, and reference to a single broad form is not intended to limit the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] 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 processing 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 an example of a system for conveying building materials; Figure 4 is a schematic diagram of an example of a working head incorporating a nozzle; Figure 5 is a schematic diagram of another example of a feed head; Figure 6 is a schematic diagram of another example of a feeding head combined with a robotic 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 three-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 of a 3D printer; Fig.11 is a schematic diagram of an alternative example of a 3D printer; Figures 12 to 14 is a schematic diagram of an example of an articulated feed head of a material conveying system; Fig.15A is a schematic diagram of an example of an articulated feed head of a material processing and material conveying system; Fig. 15B is a schematic diagram of an example of an articulated feed head of a material processing and material conveying system; Fig.16 is a schematic diagram of another example of articulation of a feed head of a material conveying system; Figures 17 to 19 is a schematic diagram of another example of a feed head articulation of a material working and conveying system; Figures 20 to 22 is a schematic diagram of another example of work head articulation of a material conveying system; Fig.23A is an end view of an example of a prior art configuration of a concrete pump; Fig. 23B yes Fig.23A The plan view of the concrete pump; Fig.24 is a plan end view of an embodiment of a concrete pump; Fig.25A is a schematic diagram of an example of a system for working building materials; Fig.25B yes Fig.25A Schematic diagrams of alternative views of a working machine; Fig.25C yes Fig.25AA schematic diagram of an example of a working head of a working machine, including a leveling rod working component; Fig.25D is a schematic diagram of an example of working parts of a wire tie; Fig.25E is a schematic diagram of an example of the working parts of a helicopter trowel; Fig.26A is a schematic diagram of another example of a system for working building materials with the boom in a folded position; Fig.26B yes Fig.26A Schematic diagram of the system; 26A, wherein 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 trowel; Fig.27B is a schematic diagram of an example of a leveling bar including an extendable trowel; 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

[0039] The following description explains a variety of different systems and methods for delivering building materials into an environment. For purposes of this description, the following definitions apply to the terms used throughout.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] The term "robotic arm" is a programmable robotic arm. In this specification, the robotic arm includes a multi-axis articulated arm, a parallel mobile robot (such as a Stewart platform, a Delta robot), a spherical geometry robot, a Cartesian robot (a robot with orthogonal axes of linear movement), etc.

[0045] 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.

[0046] The term "working head" refers to a programmable mechanical manipulator capable of processing 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 process building materials.

[0047] When a "head" has the dual function of conveying and processing building materials, the "head" can be regarded as a working head or a feeding head, and the two terms should be regarded as interchangeable in this case.

[0048] 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 jib 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.

[0049] 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.

[0050] 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.

[0051] CNC (Computer Numerical Control) is used to automate machine processing by executing pre-programmed machine control command sequences through a computer / processor / microcontroller.

[0052] Within a CNC control system, 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.

[0053] These coordinate transformations are usually applied in a static manner to resolve static coordinate offsets or to correct static errors.

[0054] 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.

[0055] Measuring the position of the robot end effector close to the TCP in real time improves 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.

[0056] Now refer to Figure 1A , 1B and Figure 2 Describe an example system for processing building materials in a physical environment.

[0057] exist Figure 1A In the example of the system 100, the system 100 includes a base 141, a boom 142 extending from the base, and an articulated work head 150 connected near the end of the boom 142, the work head including a working component 153 configured for processing building materials. A controller 130 is also provided to control the movement of the boom 142 and the work head 150, thereby allowing the movement of the working component to be controlled so as to process building materials in the environment.

[0058] 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.

[0059] In this example, the work head 150 includes a support 111, a robotic arm 125, and a work component 153. The work head 150 is positioned relative to an environment A, which is shown as a 2D plane in this example, but in practice can be a 3D volume of any configuration. In use, the work component 153 is used to process building materials within the environment E, for example, to scrape, smooth or polish concrete, to shape concrete into a specific shape, etc. The specific form of the work head 150 will vary depending on the preferred embodiment and the nature of the work to be performed, and further examples will be described in more detail below.

[0060] The work head 150 is supported by a robot base actuator 140, which can be used to move the robot base. In this example, the robot base actuator is in the form of a boom assembly, including a boom base 141 and a boom 142 including a plurality of boom elements. The boom is typically controllable, allowing the position and / or orientation of the robot base to be adjusted. The type of movement available will vary depending on the preferred embodiment. 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 and rod 142, 143 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 hydraulic actuators, thereby allowing the work head 150 to be located in a desired position relative to the environment E, and therefore relative to the building material.

[0061] The system 100 may include a tracking system 120 capable of tracking the movement of the work head, and in a specific example, tracking the movement of the work head relative to the environment. In one example, the tracking system includes a tracker base 121, which is generally statically positioned relative to the environment E, and a tracker target 122, which is mounted on the support 111, allowing the position of the work head 150 relative to the environment E to be determined. However, it should be understood that other tracking devices may be used. For example, other position / movement sensors, such as an IMU (Inertial Measurement Unit), may be used in addition or alternatively, as will be described in more detail below. Therefore, the current example is for illustrative purposes only and should not be considered limiting.

[0062] The control system 130 is in communication with the work head 150 and optionally with the tracking system 120, allowing the work 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 appreciated that multiple processing devices and / or memories may be used and any component may include a plural configuration. In use, the memory stores control instructions, typically in the form of application software or firmware, which are executed by the processor 131, allowing signals from the tracking system 120 and the work head 150 to be interpreted and used to control the work head 150 to allow material processing to be performed.

[0063] Figure 2 An example of control system 130 is shown in greater detail.

[0064] In this example, the control system 230 is connected to a work head controller 210, a tracking system controller 220 and an arm controller 240. The work head controller 210 is connected to one or more actuators 211, 212, which can control the positioning of the work part 153. The tracking system controller 220 is connected to the tracking head 221 and the target 222, thereby allowing the tracking system to be controlled and the relative position of the tracking head 221 and the target 222 to 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. 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 working 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 mentioning a single actuator does not mean to limit the present invention.

[0065] Any of the working head controller 250, the tracking system controller 220, the second tracking system 225 and the boom controller 240 generally include an electronic processing device, which cooperates 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 working head controller 250, the tracking system controller 220 and the boom controller 240 generally constitute components of the boom assembly, the working head 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.

[0066] The control system 230 generally 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 work head controller 250, the tracking system controller 220, and the boom 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.

[0067] In use, the processing device 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.

[0068] Thus, it will be appreciated that the control system 230 may be formed by any suitable processing system, such as a personal computer suitable for programming, a 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 memory (e.g., a hard disk), although this is not required. However, it should also be appreciated that the processing system may be any electronic processing device, such as a microprocessor, a microchip processor, a logic gate configuration, optionally firmware associated with an implementation logic, such as an FPGA (field programmable gate array), or any other electronic device, system or arrangement.

[0069] It should also be understood that the arrangements described above are for illustrative purposes only, and that various different systems and related control configurations may be utilized in practice. For example, it should be understood that the processing allocation between controllers and / or control systems may vary according to preferred embodiments.

[0070] Examples of systems for laying blocks are described in US8166727, WO2009 / 026641, WO2009 / 026642, WO2018 / 009981, WO2018 / 009986 and WO2019 / 014701 and US20210379775, the contents of which are incorporated herein by cross-reference. However, in this example, the device is not laying blocks, but is configured to process building materials through working parts, which in turn leads to many different factors that affect implementation.

[0071] 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 long. In this case, the boom is often subject to various loads, including forces due to movement of the boom and / or work head, wind loads, mechanical vibrations, etc., which in turn may cause oscillations or other movements at the end of the boom, which in turn may cause the robot base to move relative to the environment. This movement is often referred to as unintentional movement (unintentional movement).

[0072] In addition, the work head can be moved in a controlled manner by actively moving the arm. This is often used to move the work head during material processing, such as moving a leveling component along a work path, and this type of movement is often referred to as intentional movement.

[0073] Furthermore, due to the relative sizes of the two, particularly the boom being of the order of tens of metres and the head mechanism being one metre or less, any movement of the boom is necessarily slower than movement of the head.

[0074] Therefore, in practice, when using the system, it is usually necessary to guide the working parts in order to process the building materials in a specific location or area. For example, when leveling a floor or concrete slab / foundation, it is usually necessary to guide the leveling member to perform multiple back and forth operations on the floor or concrete slab / foundation area.

[0075] In this process, the rough movement of the working part is achieved by moving the arm, such as by rotating the arm and adjusting the arm length, so that the working part roughly passes through the expected working path. At the same time, the working head 150 can be controlled to provide fine position adjustment and specifically ensure that the working part follows the expected working path. This is done not only to offset the unintentional movement of the end of the arm, but also to overcome the limitation of the ability to accurately control the end of the arm by moving the arm alone.

[0076] It will therefore be appreciated that in the above arrangement the boom moves with a slower dynamic response over a larger distance, while the work head provides a faster dynamic response over a smaller distance, and the controller simultaneously controls the boom and work head to move the working part to process building materials.

[0077] 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".

[0078]

[0111] In any event, it will be appreciated that a combination of fine and rapid response of the work head can be used to address limitations in the ability to precisely control the end of the boom, and can also be used to address problems with unintentional movement of the end of the boom. Applicants refer to this form of operation as DST (Dynamic Stabilisation Technology) and have described it in prior publications, including US8166727, WO2009 / 026641, WO2009 / 026642, WO2018 / 009981 and WO2018 / 009986, the contents of which are incorporated herein by cross-reference.

[0079] Examples of a number of different aspects of the above-described system will now be described in more detail. These different aspects of the system may be used independently, or may be used in combination, depending on the preferred implementation. It will be understood that reference to individual aspects should not be considered limiting, and that these aspects may be used in any number of different combinations, depending on the preferred implementation and the scenario in which the system is used.

[0080] As described above, the controller may be configured to control the boom and the work head to control the movement of the work member during the processing of the building material, in particular, for example, leveling or otherwise processing the building material along a desired working 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 work member relative to the working path, and simultaneously control the work head to move the work member to provide precise positioning of the work member as it moves relative to the path. This in turn allows the building material to be processed continuously or at least substantially continuously as the work member moves, thereby ensuring continuity of processing and, therefore, ensuring fine processing of the building material.

[0081] To achieve the desired control, the work head is typically articulated in at least two axes to move the nozzle with two degrees of freedom, thereby allowing movement of the nozzle in two orthogonal spatial directions. In this regard, it should be understood that reducing the articulation degrees of freedom of the work head will reduce the complexity of the work head, but may be at the expense of limiting the accuracy of positioning and / or movement of the working parts in other spatial directions or orientations. Therefore, the specific configuration of the work head can vary depending on the specific use scenario.

[0082] For example, the work head can be configured to move the work piece in the horizontal spatial direction to correct for the longitudinal and lateral movement of the boom end. This allows correction and / or compensation for the rotation and extension / retraction movement of the boom. In this example, the vertical movement of the boom is not compensated, but this may be less important in some cases.

[0083] 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 boom extension / retraction or rotation and boom end height.

[0084] In other applications, the work head may be articulated in three axes to enable movement of the work component with three degrees of freedom, thereby allowing movement of the work component in orthogonal spatial directions, which can be used to correct for longitudinal, lateral and vertical movement of the boom end.

[0085] To provide three degrees of freedom of movement, the work head may be articulated in various ways, for example, providing the work head with axes to provide one of: pitch, roll, pitch motion; pitch, pitch, roll motion; or pitch, roll and slide motion. Further examples of such arrangements are described in more detail below.

[0086] Although not required, in some arrangements, the work head can be articulated on another axis (or a third axis in a two-dimensional spatial motion arrangement) to adjust the pitch of the work piece. Similarly, the work head can be articulated on another axis to adjust the orientation of the work piece (e.g., to adjust yaw and / or roll).

[0087] However, this is not required and, for example, a fixed workpiece orientation and pitch may be used, depending on the nature of the workpiece and the machining action being performed.

[0088] The work head may be articulated using a variety of different arrangements, 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, an electric servo system, etc. The exact nature of the actuator will vary depending on the preferred embodiment, and some examples are described in further detail below.

[0089] In one example, the working head includes a robotic arm and an end effector, wherein the working component is supported by the end effector, although this is not required and in other examples, the working component is directly integrated into the working head without a separate end effector.

[0090] In one example, the working component can be used to perform any of a variety of processing actions. Examples of processing actions include flattening a material to ensure a level surface, or shaping a material to form a particular shape as the material cures or otherwise solidifies. Example working components include, but are not limited to, a leveling component; a trowel; a template; a mold; a biasing member configured to push a working material; a cutting tool; a grinding head; a polishing head; a washer head; a sandblasting head; and a cutter, etc.

[0091] In some examples, the work head also includes a nozzle configured for conveying building materials. In this example, the working part can be provided in a fixed arrangement relative to the nozzle, which may be sufficient to ensure that the required work is achieved according to the usage scenario. For example, a template can be attached to the nozzle to shape the building material when conveying the material, such as guiding the material into a generally rectangular shape for use when building a wall or the like. However, in other examples, the work head can be hinged to allow adjustment of the position of the working part relative to the nozzle. This can be used to move the working part relative to the nozzle, such as allowing the working part to rotate around the nozzle, so that the working part can be provided in a trailing arrangement according to 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 direction of the working part, which is important in, for example, leveling operations.

[0092] In one example, the work 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 the height and / or position of the work piece to be adjusted. This can ensure that the work piece can be held in a particular orientation, such as vertical, while also allowing the height of the work piece to be controlled separately as the arm and / or work head moves.

[0093] The work 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 to allow horizontal movement to ensure that all parts of the surface can be leveled.

[0094] 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 similar device).

[0095] As also mentioned above, the system typically includes a tracking system configured to measure the position and / or movement of the work head, the boom end, the boom and / or the working part. In this regard, due to the kinematic characteristics of the work head, the position of the working part relative to the boom end is known, so once one of the above positions is known, the other positions can usually be easily derived. The controller is then typically configured to control the work head based on the signals from the tracking system.

[0096] The nature of the tracking system will vary depending on the implementation. For example, the tracking system may include one or more 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 range sensor, or an ultrasonic range sensor.

[0097] For example, in a specific configuration, the tracking system 120 includes a tracking base 121, which includes a tracker head, and a base sensor for sensing reflected rays, the tracker head having a ray source, which is arranged to send a ray beam to a target 122. In one example, a base tracking system is provided, which tracks the position of the target 122 and controls the direction of the tracker head to follow the target 122. The target 122 generally includes a target sensor that senses the ray beam and a target tracking system that tracks the position of the tracking base 121 and controls the direction of the target to follow the tracker head. Angle sensors are set at the head and the target to determine the direction of the head and the target. The tracker processing system determines the relative position of the tracker base and the target based on the signal from the sensor, and in particular uses the signal from the angle sensor to determine the relative angle between the tracker and the target, and the flight time of the ray beam can be used to determine the physical distance. In another example, the ray can be described by polar coordinates to determine the direction of the base relative to the tracking head. Although a single tracking system 120 including a head and a target is shown in the figure, this is not necessary. In other examples, multiple tracking systems and / or targets can be provided, as described in more detail below.

[0098] 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.

[0099] 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 a frequency of 300 Hz, 1 kHz, or 2 kHz (depending on the device) and rely on a combination of multiple sensing devices, including laser guides, vision systems using 2D cameras, accelerometer data (e.g. from tilt sensors or INS (Inertial navigation System)), which can be used to make precise position measurements of the laser tracker and the active target. The data obtained is equivalent to the position and optional orientation of the active target relative to the environment E. Since these systems are known and commercially available, they will not be described in detail.

[0100] 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 processing scenarios, high accuracy may not be as important. For example, in some cases, the precise positioning of the workpiece is not as critical. Due to the higher cost of laser tracking systems, in these cases, more basic tracking systems can be used. For example, a combination of GPS and IMU can provide sufficient accuracy.

[0101] 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 the work path. Thus, in this example, a laser beam can be used as a path for the work part to move, with the optical sensor detecting deviations from the beam and the controller compensating by adjusting the work head as needed.

[0102] Some specific applications and usage scenarios are described in more detail below.

[0103] 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 for placing blocks) can be dynamically stabilized by the applicant's proprietary dynamic stabilization system (DST), which is described in prior 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.

[0104] 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 caused by dynamic forces acting on the robot or its support. The system uses at least one robot with a dynamic response that is faster than the dynamic input being compensated. In one non-limiting form, the DST system includes a first robot with a slow dynamic response for roughly positioning the end effector, and a second robot coupled to the first robot and mounted with an end effector, the second robot having a fast dynamic response for finely positioning the end effector. In this way, 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 accurately controlled in real time, thereby allowing the end effector to move accurately and quickly relative to the environment.

[0105] Embodiments of DST-enabled long-arm machines for construction 3D printing, concrete pumping, and conveying material processing (e.g., screeding) are disclosed herein. These machines enable the end effector (e.g., conveying nozzle, screed head) to be dynamically stabilized (i.e., continuous path DST) as the arm traverses the work area.

[0106] A number of examples will now be described in which the boom includes a feed head incorporating a nozzle for delivering building material. Next, an example will be described in which the feed head also includes a working component, so that the head is actually a combined feed head and working head. Finally, some examples will be provided that only incorporate a working head with a working component. It will be understood from the following that the concepts between delivery and working are largely interchangeable, and the concepts described with respect to the feed head can also be applied to the working head, as will be understood by those skilled in the art.

[0107] In all the following drawings, similar reference numerals are used to indicate similar features, and the hundreds digit of the reference numerals is numbered with the corresponding figure number. For example, the arm in Figure 1 is marked as 142, Figure 3 The arm bracket in is marked as 342.

[0108] The following Figure 3 An example of a concrete pump is shown, comprising a vehicle 341, wherein a delivery head 310 is connected to the end of a boom 342, replacing the normal hanging hose used in conventional concrete delivery devices.

[0109] The articulated feed head 310 has three rotating joints A, B, C, which are arranged in an articulated member 312, which supports a nozzle 313, which is used to deliver the building material M. The member 312 can be part of a robot arm or other manipulable structure, which is used to support 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.

[0110] The first pitch joint A pivots in the boom plane about a horizontal axis parallel to the boom articulation joint with the horizontal axis. Joint B provides rolling motion. Joint C provides a second tilt axis. By combining the movements of A, B and C, the end of the nozzle 313 can move in three linear orthogonal dimensions. For concrete delivery, the angle of the nozzle is not important. The common size of the two connecting rods is about 500mm long. With an angular movement of about + / -15 degrees on B and C, the linear movement at the nozzle is about 500×Cos15°=+ / -130mm.

[0111] 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 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 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 provides slow dynamic response movement over a larger range, while axis ABC provides fast dynamic response over a smaller range.

[0112] Other sensing and guidance scenarios include: a) Maintaining constant height by sensing a rotating laser plane with a PSD (Position Sensitive Detector). b) Following a wire or guide rope similar to a curb machine guidance system. c) Following a laser line. d) Following a track by measuring a DGPS (Differential GPS) signal, where fine movements are measured by an IMU (Inertial Measurement Unit). e) Machine vision. f) Ultrasonic distance sensors for maintaining height above the ground. g) Laser trackers or total station optical measurements.

[0113] For concrete pouring, the concrete needs to be leveled first to get a flat surface. Figure 4A feed head 410 is shown including 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 can be moved in a trailing position relative to the delivery nozzle and the arm. Joints E, F and G provide three-axis wrist motion to keep the leveling arm horizontal while the sliding axis H remains vertical. Axis H allows the height of the leveling rod to be adjusted. Axis J provides rotation about the 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.

[0114] For 3D printing, nozzle orientation can be important. Figure 5 Shown with Figure 3 A similar articulated feed head 510 in which an additional member 514 is attached to the articulated member 512, the additional member 514 having axes D, E, F providing wrist directional movement and delivering material through a conduit to a trowel nozzle 513 rotating about axis G.

[0115] Measurement, stability and control allow long arms to accurately deliver material and complete screed or trowel work. The above example uses a large pipe diameter, compared to using a hose, which allows for high flow rates and large aggregates. It is well known that high pressure allows for long distance pumping. Standard concrete pump pipes and fittings are easy to clean and highly reliable.

[0116] 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.

[0117] 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).

[0118] 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 precisely positioned in three-dimensional space.

[0119] Figure 6A 3D printing nozzle 613 is shown which may be optionally mounted to a laying fixture of a robotic arm 612 of a laying head 610 of a Hadrian X machine, such as described in previous publications including US8166727, WO2009 / 026641, WO2009 / 026642, WO2018 / 009981, WO2018 / 009986 and WO2019 / 014701 and US20210379775. This could be used as a low cost demonstration for use with existing Hadrian X equipment. Or it could be used to level an uneven slab or foundation, either the entire slab, or just where blocks are to be laid. Or it could be used to 3D print in conjunction with automated block laying, for example allowing the end effector 612.1 of the robotic arm 612 to lay blocks, followed by grabbing the nozzle to apply mortar to the block layer.

[0120] Figure 7 A variation of this concept is shown where a 3D printing and mortar application nozzle 713 is permanently mounted to a laying jaw 712.1 of a robotic arm 712 of a Hadrian X block laying machine, with a conduit 715 (e.g. a rubber hose or articulated steel pipe) used to deliver building material (e.g. 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.

[0121] Figure 8 A replacement head 810 for the robotic arm of a Hadrian X block machine is shown. In this example, the head 810 includes a bracket 812.1 pivotally mounted to an arm 842 about a horizontal axis, to which a linear actuator arm 812.2 is rotatably mounted about an orthogonal axis, thereby providing stable motion in three axes. The system can utilize the triple tracker arrangement described in US20210379775, the contents of which are incorporated herein by cross-reference. Specifically, the triple tracker tracking arrangement includes three tracker targets 822 mounted on the arm 842 of the block machine, which can be detected by a laser tracker.

[0122] The arrangement of this embodiment includes a tracking base disposed in an environment, the tracking base including a tracking head bracket and at least three tracking heads mounted on the tracking head bracket. Each tracking head includes a radiation source, a base sensor for sensing reflected radiation, at least one tracking head actuator for controlling the direction of the tracking head, and at least one tracking head angle sensor for monitoring the direction of the tracking head. The radiation source is used to send a beam of radiation to a corresponding target. The target system includes at least three targets 822 mounted on the arm, each target including a reflector for reflecting the beam of radiation to the base sensor of the corresponding tracking head. In this arrangement, the control system causes each tracking head to track the corresponding target as it moves in the environment, and determines the position of each target relative to the corresponding tracking head at least in part using signals from each base sensor and at least one tracking head angle sensor. Then, the control system uses at least in part the 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.

[0123] 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, which tracks a retroreflector 922 mounted on the nozzle 913 and / or the actuator arm 912.2. The retroreflector can be rotated about the nozzle to maintain line of sight with the tracker.

[0124] 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 (such as produced by Putzmeister or Schwing).

[0125] Fig.11 Shown is a boom 1042 folded and loaded onto a vehicle 1041 and a hopper trailer 1164 containing 3D printing material.

[0126] It is understandable that a concrete pump boom can be used in these configurations even though the boom tip of a conventional concrete pump boom is not dynamically stable. The addition of a feed head incorporating the type of DST (Dynamic Stability System) described above enables 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), requiring CNC (Computer Numerical Control) control of the boom, so a standard concrete pump would need to be modified and customized to accomplish the task. Ideally, the custom machine would feature a lighter boom and smaller pipes (e.g. 40mm diameter instead of 100mm diameter).

[0127] Fig.12 A system is shown comprising an arm 1242 and 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 Bl. This arrangement enables three-axis motion of the nozzle tip through all revolute (articulated) joints (pitch-pitch-roll or PPR joint sequence).

[0128] Fig.13 A system comprising an arm 1342 and a feed head 1310 is shown, the system having a single articulated member 1312 for supporting a nozzle 1313 and having articulated joints on axes A1, A2 and B1. This arrangement achieves a nozzle tip similar to Fig.12 The three-axis motion shown in , but with a different joint order (pitch-roll-pitch or PRP), achieves the desired three-axis motion of the nozzle tip through all revolute (articulated) joints.

[0129] Fig.12 and 13 The concept of the robot or arrangement in is that the joints (A1, A2, Bl) move the articulated member 1212 to move the end of the nozzle 1313. Although this movement will change the direction of the nozzle slightly, for 3D printing applications, this is insignificant compared to the small DST correction movement required. Low response rate DST will be applied to the arm, while high response rate DST will be applied to the nozzle robot.

[0130] A further embodiment of a feed head for a concrete pump or a large robot arm is Figures 14 to 22 Shown in.

[0131] Fig.14 A three-axis fine manipulator is shown at the end of a concrete pump boom 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 driven by hydraulic servos or electric servos to stabilize the tool center point (TCP). Stability can be achieved by inertial measurements to limit the acceleration of the TCP. Stability can also 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.

[0132] In another optional mode of operation, the A and B axes may not be stabilized and may be controlled individually to allow precise positioning of the nozzle without the need to move 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, such as the boom moving along a linear path and the A and B axes moving the nozzle left and right to distribute concrete over a wider area. Or, for example, during the process of the boom filling a rectangular column, as the boom moves the nozzle upward, the A and B axes may direct the nozzle toward the rebar and formwork around the edge of the column.

[0133] It should be noted that in the example above, the nozzle is shown pointing vertically downward. In another example, the nozzle can be pointed more horizontally and used to spray materials such as shotcrete, allowing construction materials to be delivered to vertical or inclined surfaces.

[0134] 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 follow a work path during processing, such as automatically placing concrete on a slab or pouring it into a formwork, spraying concrete, or placing 3D printed building materials.

[0135] Fig.15A An apparatus is shown comprising 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 comprises a "kerbstone" type forming trowel 1571, which is mounted on the end of the nozzle and rotated about axis P using a rotary actuator 1516.4. This would allow the arm to lay kerbs, or to build walls by stacking layers of kerbs. The kerb head with an internal reciprocating plunger 1571.1 allows the compaction of concrete to perform a full troweling operation and produce a high quality void-free product. As Fig. 15BThe cutter 1572 is shown mounted to the nozzle and / or feed head using a linear actuator 1572.1, which allows the cutter to be positioned at will so that the construction of the curb or wall can be started at a specific location by holding the feed head stationary while the concrete is pressed onto the feed head using a biasing mechanism (e.g., 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.

[0136] 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 limited range of motion to limit the angular variation of the curb head. The A and B axes only need to move enough to correct for the accuracy of the boom and the amount of lateral bounce.

[0137] 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 an electric servomotor 1616.12, 1616.22 can be used to move the A and B axes, and a rack 1616.31 and pinion 1616.32 can be used to move the Z axis. It also shows material M being conveyed synchronously with the reinforcement 1601.

[0138] 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.

[0139] Fig.17 Shown with Fig.16 A similar arrangement 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 pinion 1716.42. The C and W axes allow the leveling rod to get into corners and also to move side to side or sweep in an arc pattern to move, distribute and level the concrete, resulting in a level concrete Ms. Alternatively, the bracket 1712.3 can be rotatably mounted to the nozzle 1713 so that the leveling rod 1751 follows the nozzle.

[0140] 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 relatively 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 movement can be programmed to keep the leveling bar TCP on the path. For example, one end of the leveling bar can be set to the TCP, and then the boom and leveling bar can be programmed to make the leveling bar TCP follow the edge of the board along the formwork. Note that a laser or a taut metal wire (rope) 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 an electromagnetic proximity sensor via a PSD sensor.

[0141] The boom can learn entire movements or boundaries of movements. For example, it can manually guide the boom around the edge of a slab, or to the corner of a polygon, then switch to automatic mode to automatically fill a polygon or other set shape with concrete, and then switch to leveling mode to level, trowel and smooth concrete.

[0142] The leveling bar can be replaced (via quick connect) by a "trowel", helicopter trowel, trowel or other tool.

[0143] Fig.18 Shown with Fig.17 A similar arrangement with the addition of a chute 1752 connected to the actuator 1716.7 which can rotate about axis D to distribute the concrete. This allows a longer screed bar to be used and with each "sweep" of the main boom, concrete can be poured over a wider area. The chute can be manually controlled, programmed to follow the TCP, or programmed to oscillate or rotate. A typical action is to program the boom and screed bar to the TCP trajectory to lay a slab of concrete "diagonally" from a corner, while the chute oscillates to distribute concrete over approximately half the width of the screed bar.

[0144] It is important to keep the screed bar moving perpendicular to the W axis so that it can push directly against the concrete. This will allow the screed bar to operate in the desired pattern, such as a figure 8 operation where the screed bar pushes concrete onto previously laid concrete and then levels it into the new area.

[0145] Fig.19 Shows something like Fig.18 arrangement, except that the chute 1852 is replaced by a pipe 1953 and is driven by a rotary drive or hollow reducer 1916.7.

[0146] Fig. 20 Shows something like Fig.18The arrangement is similar to that of 2010 except that the sliding linear Z axis is replaced by a J-shaped articulated arm 2018 having rotary actuators 2018.1, 2018.2 at both ends 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).

[0147] 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, but not the sideways (boom rotation) movements. 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 robot arrangement which allows vertical and horizontal movement within the vertical plane of the boom. The nozzle end 2113 can freely pivot and be aligned by gravity and can support the hose. This arrangement requires only two additional axes of motion and is essentially effective in providing precise control of the end of the pipe, but of course will not correct for movement in the direction of boom rotation.

[0148] Fig. 22 A 5-axis fine manipulator integrated into the end of a concrete pump boom 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 the position and orientation of the delivery nozzle to be corrected and compensated. Note that an additional sixth axis (not shown) may be added to position, for example, a trowel or leveling device. In the arrangement shown, the delivery nozzle is directed substantially horizontally in the spraying posture of the shotcrete. For example, the device may spray the shotcrete onto a wall or wall formwork or reinforcement, which is then troweled and applied to 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 positioned in a vertical posture, which is a typical orientation for casting slabs. It should be understood that the other components described previously (chute, pipe, trowel rod, etc.) may also be added to this arrangement.

[0149] Another aspect of the present disclosure relates to a pump for pumping concrete.

[0150] Prior art uses a double piston pump to pump concrete, and reference will now be made to Fig.23A and 23BAn example is described. Generally, the dual piston pump has hydraulic cylinders 2383 and 2384, which push corresponding pistons in cylinders 2381 and 2382, and cylinders 2381 and 2382 are selectively connected to a feed pipe 2386 through a swing valve 2385. Concrete enters the pump cylinder and is squeezed out by the pistons pushed by the hydraulic cylinders 2383 and 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 corresponding pistons in the cylinders 2381 and 2382 alternately pump and fill concrete.

[0151] The intermittent nature of the delivery flow in the feed pipe creates large impact forces and intermittent flow of concrete, which causes the boom to bounce. The bouncing fatigues the boom structure, the dynamic pressure fluctuations fatigue the pipe, and the bouncing boom makes the concrete delivery inconsistent. The flow rate changes make it difficult or even impossible to deliver concrete to the intended path. The flow rate changes also make it difficult to deliver concrete evenly to the slab, so a lot of manual movement of concrete (via rakes, levelers, shovels, etc.) is required to move the concrete to the correct location.

[0152] Fig.24 The purpose of the improved pump arrangement shown is 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 rate 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 decelerates, the second piston accelerates precisely, just to maintain a constant flow rate. When the second piston stroke is close to the end, the first piston stroke accelerates. Preferably, the position of the hydraulic piston is measured by a linear encoder, such as a Temposonics cylinder rod encoder or 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.

[0153] 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 quickly enough, more pump cylinders can be used.

[0154] The pump can be used to deliver 3D printing materials that require high pressure and continuous flow.

[0155] The pump can be used for concrete pump arm delivery along the TCP to control the delivery of concrete evenly to the slab or mold or formwork.

[0156] The pump can be used to transport 3D printing materials over long distances.

[0157] Piston pumps have a longer life than peristaltic or screw pumps, are capable of higher pressures, and have better wear resistance than gear pumps.

[0158] An example of a processing machine for processing building materials will now be described.

[0159] Reference now Figures 25A to 25E , showing a DST assisted concrete leveling pole and helicopter trowel that can work in conjunction with a concrete boom pump.

[0160] In this example, a concrete conveyor 2590 is provided, which may be similar to the concrete conveyor described above, or may be an existing concrete conveying system, including a truck mounted or tower crane column high rise concrete boom pump, depending on the specific application.

[0161] 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, which is similar in form to the feeder head described above. The working machine is used in conjunction with a tracking system 2520 similar to that 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.

[0162] like Fig.25C As shown, in one example, the work head includes a leveling rod 2551 mounted on an articulated member 2512, and the articulated member 2512 includes a linear actuator 2512.2 to allow the workpiece to be raised and lowered. The articulated member 2512 is attached to the arm through a rotating joint 2512.1, allowing the direction of the articulated member 2512 to be changed, thereby changing the direction of the leveling rod 2551.

[0163] This arrangement is primarily used for concrete leveling, however, the tool head can be used with levelers and helicopter trowels (or lighter trowels) 2572 (e.g. Fig.25E as shown) or steel bar connector 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.

[0164] The workhead does not necessarily need to have all 6DOF corrected using DST, but that 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. Semi-automatic operation works best when the operator uses the joystick to control the XY plane position of the boom 2542 (the control system will do the motion transformation and calculate the required boom roll, lift, pitch and extension angles) and uses the joystick or lever to control the angle of the screed bar. The roll, pitch and Z axis motion of the screed bar working part (and the Z axis of the boom) will be automatically controlled by the DST. The operator can have manual control to be able to lift the working part in the Z axis direction for retracting or handling large piles of concrete, but there will be a "virtual floor level" that the operator cannot go below (unless some kind of override button is pressed). For troweling work that requires multiple passes, a "teach mode" can be used where the boom learns the movements and the operator can then repeat them, such as the left joystick controlling the "feed rate" of the boom and the right joystick controlling the rotation speed of the trowel (the troweling speed will need to change as the concrete cures).

[0165] 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 as an independent second boom to a concrete pump truck, or can be retrofitted to an existing truck-type boom, such as a Hiab, Effer. The boom can also be mounted on a tower crane column to work in conjunction with a high-rise concrete boom pump.

[0166] Additional telescopic stages can be added to meet any reach requirement. Typical concrete pump booms have a reach range of 20m to 60m. For example, a 32m reach boom can be used as a mid-range option with far greater practicality than a 5m reach "self-leveler" (Lichine Screed saver Boss or Dragon Screed).

[0167] It will be appreciated that the articulated telescopic boom assembly can be used in conjunction with the concrete pump boom. A work head can also be added to the boom of the excavator as an attachment.

[0168] A LiDAR sensor on the head of the leveling pole can be used to provide safe presence sensing. The LiDAR will operate above the leveling pole height.

[0169] Figures 26A to 26C Further shown is a DST-enabled leveling head attached to the end of a long boom.

[0170] In this example, the work head 2610 is connected to the arm 2642. Fig.26A and 26BIts folded and extended positions are shown respectively.In this example, the levelling bar 2651 is connected to an articulated member 2612 comprising a linear actuator 2612.2 and to the arm via a swivel joint 2612.1, 2612.3 to allow movement in three degrees of freedom.

[0171] As an alternative to the interchangeable head that allows the use of a screed or helicopter trowel, an example is provided that includes a screed pole that can be attached or deployed, see Fig.27A and 27B shown.

[0172] 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. The example provides a spatula element 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 may be hingedly mounted to the leveling rod 2751 so that they can be folded into place and secured in place using the connecting rod 2753.

[0173] This avoids having to plug in a separate helicopter spatula via a detachable connection.

[0174] 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.

[0175] A texture brush, broom or roller (for surface texturing) or a grooved trowel may also be installed to smooth out expansion joints.

[0176] A powder dispensing unit may be installed to dispense cement powder, hardeners, pigments, acids, paints, liquid membranes (e.g. moisture evaporation inhibitors, accelerators, membranes, etc.). A roll material dispenser may also be installed, such as plastic film 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.

[0177] Of course, other accessories such as grinding heads, drill bits, etc. can also be installed.

[0178] Regarding the head position measurement, in order to reduce the cost of laser trackers, such as Fig.28 As shown, a standard rotary laser level and machine position sensitive detector (PSD) can also be used.

[0179] In this example, the leveling rod 2851 is rotatably mounted to an articulated member 2812 using a rotary servo motor 2812.4, allowing the leveling rod to rotate. Three PSDs 2882 are arranged to measure three points on the plane. In order to allow a good line of sight when the boom is rotated above the construction site, the three PSDs are mounted on a frame that rotates about the Z axis. The PSDs only receive 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, optionally at each PSD position. The XY position of the leveling rod is not important, as its task is to establish a flat plate.

[0180] The rod extension is quite long and a long enough hydraulic ram would be heavy. So a chain / pulley or rope system would be needed to "speed up the movement". It would probably be easier and better to servo drive it via a rack. Putting the rack at the top of the rod with low clearance telescoping sidewalls and continuous support at the bottom of the inner rod means the structural support of the rod is good. Fig.29 An example rod extension arrangement using UHMPE (UltraHigh Mechanical Polyethylene) is shown.

[0181] 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.

[0182] 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.

[0183] It will be appreciated by those skilled in the art that various changes and modifications will become apparent. All such changes and modifications apparent to those skilled in the art should be considered to fall within the broad spirit and scope of the invention as 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 work head connected adjacent an end of the boom, the work head including working components configured for processing building materials; and d) A controller configured to control movement of the boom and the work head to move the work member and thereby process the building material, wherein the boom has a slower dynamic response over larger distances and the work head provides a faster dynamic response over smaller distances.

2. The system according to claim 1, characterized in that The controller is configured to control the work head to dynamically stabilize the work member 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 work head to control movement of the work member during processing 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 work head to process the building material along a work path.

5. The system according to claim 4, characterized in that When processing building materials, the controller is configured to: a) controlling the boom to move the boom end to provide coarse guided movement of the working member; and b) Control the working head to move the working part, thereby achieving precise positioning of the working part.

6. The system according to claim 4 or claim 5, characterized in that: The controller is used to control the boom and the working head so that the boom and the working head move simultaneously.

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

10. The system according to claim 9, characterized in that The movement of the working parts 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 work head is articulated with the axis 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 working head is further hinged on another axis to adjust the pitch movement of the working part.

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

14. The system according to any one of claims 1 to 14, characterized in that The working 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 working head includes a robot arm and an end effector, wherein the working part is supported by the end effector.

16. The system according to any one of claims 1 to 15, characterized in that Working parts include one of the following: a) Leveling the parts; b) Trowel; c) Templates; d) Mould; e) a biasing member configured to push the material being processed; f) cutting tools; g) Grinding head; h) Polishing head; i) Washer head; j) blasting heads; and k) Cutting machine.

17. The system according to any one of claims 1 to 16, characterized in that: The working head is articulated to at least one of the following: a) permits rotation of the working part; b) control the height of the working parts; and c) Control the direction of the working parts.

18. The system according to any one of claims 1 to 17, characterized in that The working 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.

19. The system according to any one of claims 1 to 18, characterized in that The work head is articulated to allow rotation and horizontal movement of the working part.

20. The system according to any one of claims 1 to 19, characterized in that The system includes a boom actuator configured to move a boom.

21. The system according to claim 20, characterized in that The boom actuator is configured to perform at least one of the following functions: a) rotating the boom; b) Extend or retract the boom; c) deploying the boom; and d) Raise or lower the boom.

22. The system according to any one of claims 1 to 21, characterized in that The system includes a tracking system configured to measure the position and / or movement of at least one of: a) Working head; b) boom end; c) boom; as well as d) a working head; and the controller is configured to control the working head according to the signal from the tracking system.

23. The system according to claim 22, 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.

24. A system according to claim 22 or claim 23, 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.

25. The system according to claim 22 or 23, characterized in that The tracking system includes: a) a retroreflector movably mounted on an articulated head adjacent the working member; and b) Laser trackers, where the tracking system is configured to measure the position and orientation of the workpiece based on rays reflected from a retroreflector.

26. The system according to claim 22 or 23, 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 work head, the sensor being configured to detect deviation from the laser guide.

27. The system according to claim 26, characterized in that Laser guidance defines at least one of the following: a) height plane; and b) Working path.

28. The system according to any one of claims 1 to 27, characterized in that The system includes a nozzle configured to deliver building material.

29. The system according to claim 28, characterized in that The working head is articulated to at least one of the following: 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 nozzle.

30. The system according to claim 28 or 29, characterized in that The work head is articulated about three axes to allow the nozzle to be maintained in a fixed orientation, and further articulation is provided to allow the height and / or position of the nozzle to be adjusted.

31. A system according to any one of claims 28 to 30, characterized in that The work head is articulated to allow rotation and horizontal movement of the nozzle.

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