Robot building block laying machine

Abstract

A robotic block laying machine for building a block structure, the robotic block laying machine comprising: a base; a boom extending from the base; a plurality of shuttling devices, wherein each shuttling device is configured to: receive a block; and traveling along the movable arm to transport the building blocks along the movable arm; the building block laying robot is arranged at the far end of the movable arm; the building block laying robot is configured to receive the shuttle device from the movable arm; and positioning the shuttle device near the block laying location such that the shuttle device is capable of releasing and thereby laying the blocks.

Description

[0001] Priority document

[0002] This application claims priority to Australian Provisional Application No. 2022903173, filed on October 26, 2022, entitled “Robotic Construction Machine” and Australian Provisional Application No. 2023902647, filed on August 21, 2023, entitled “Robotic Construction Machine”, the contents of which are incorporated herein by reference in their entirety. Background of the Invention

[0004] The present invention relates to a robotic block laying machine for constructing block structures. Background Art

[0005] Reference in this specification to any prior publication (or information derived therefrom) or known matter is not and should not be taken as an admission, recognition or any form of implication that the prior publication (or information derived therefrom) or known matter forms part of the common general knowledge in the technical field to which this specification relates.

[0006] Autonomous and semi-autonomous industrial robotic devices are increasingly being used in outdoor work environments such as construction sites, building sites, mining sites, and industrial sites. For example, WO2007 / 076581 describes an automated bricklaying system for constructing a building using multiple bricks, comprising a robot equipped with a bricklaying and gluing head, a measurement system, and a controller that provides control data to the robot to lay the bricks at predetermined locations. The measurement system measures the position of the head in real time and generates position data for the controller. The controller generates control data based on a comparison of the position data with a predetermined or preprogrammed position of the head to lay the bricks at predetermined locations of the building under construction. The controller can control the robot to construct the building in a layer-by-layer manner, wherein the bricks are laid in sequence at their respective predetermined locations, and a full layer of bricks for the entire building is laid before the next layer of bricks is laid.

[0007] In the applicant's earlier publication WO2018 / 009981, a stand-alone vehicle-mounted bricklaying machine is provided. A truck supports the bricklaying machine mounted on a truck chassis frame. The frame supports brick bags or pallets that are loaded into the machine's loading compartment. A destacking robot then removes (i.e., removes) an entire row of bricks from the pallet and places them on a platform. A transfer robot can then pick up individual bricks from the platform and move them to a saw, router, or turntable, or between these components. The turntable is coaxially arranged with the tower and is located at the bottom of the tower. The turntable transfers the bricks via the tower to a boom comprising an articulated telescopic arm and rod elements. The bricks are transported in the articulated telescopic arm by a linearly movable shuttle in each element to the bricklaying and gluing head, where the bricks are transferred to the fixture of the bricklaying robot and laid according to the build data file. The machine described in WO2018 / 009981 has a laying rate of approximately 180-240 bricks per hour.

[0008] In the above arrangement, a single block is transferred between a plurality of modules, each of which holds the block, resulting in the block being handled multiple times before being laid. It is desirable to reduce the number of handling operations to improve the reliability of the machine.

[0009] It is also expected that the overall structure of the machine will be simplified and that the laying rate and the machine's ability to operate at more construction sites will be increased. In addition, it is expected that the machine will be able to transport other building elements, such as tiles for roofing or flooring. Summary of the Invention

[0010] In a broad form, one aspect of the present invention is directed to a robotic block laying machine for constructing block structures, the robotic block laying machine comprising: a base; a boom extending from the base; a plurality of shuttles, wherein each of the shuttles is configured to: receive blocks; and travel along the boom to transport the blocks along the boom; and a block laying robot disposed at a distal end of the boom, wherein the block laying robot is configured to: receive the shuttle from the boom; and position the shuttle near a block laying location so that the shuttle can release the blocks for laying.

[0011] In one embodiment, the block laying robot includes: a laying arm; and an end effector suspended from the laying arm for manipulating the shuttle device, wherein the end effector receives the loaded shuttle device carrying blocks, and the laying arm moves the end effector to position the shuttle device near the block laying position.

[0012] In one embodiment, the robotic block laying machine further comprises at least one transfer robot configured to pick up one of the blocks provided in the base and transfer the block to the shuttle device.

[0013] In one embodiment, the robotic block laying machine further comprises a tower rotatably mounted to the base about a boom rotation axis, the tower supporting the boom and the boom pivotally connected to the tower.

[0014] In one embodiment, the robotic block laying machine is mounted to a support frame which is in turn mounted to the chassis of a vehicle.

[0015] In one embodiment, the boom comprises a plurality of boom elements and rod elements, and at least one pivot joint is formed between the boom elements and the rod elements.

[0016] In one embodiment, the shuttle device is configured to transport the blocks through an interior of the boom.

[0017] In one embodiment, the shuttle device travels along a track provided between the base and the block laying robot.

[0018] In one embodiment, the track includes a sending track and a return track to accommodate a shuttle device going to the block-laying robot and returning to the base.

[0019] In one embodiment, the track includes a fixed track segment and a movable track segment.

[0020] In one embodiment, the movable track segment comprises a track capable of translation or rotation.

[0021] In one embodiment, the shuttle is bidirectional, traveling forward and backward.

[0022] In one embodiment, the base is configured to receive one or more packages of building blocks, and the at least one transfer robot is configured to pick one of the building blocks from the packages of building blocks.

[0023] In one embodiment, the blocks are packed in a single file in a base of the machine at a designated packing station.

[0024] In one embodiment, the blocks packages are fed into the machine onto a package conveyor module which is used to move the packages forward to an empty package station.

[0025] In one embodiment, each of the bag conveyor modules includes: a base frame; and a drive assembly comprising a plurality of chains extending along the length of the base frame between a pair of shafts and spaced apart along the width of the base frame, wherein the chains are driven by a motor connected to one of the shafts.

[0026] In one embodiment, the packages of blocks are provided on pallets and empty pallets are removed from a package conveyor module by a pallet ejection robot that picks up the empty pallets and moves them to a pallet storage location for removal from the robotic block laying machine.

[0027] In one embodiment, the pallet ejection robot includes: a slide support slidably mounted to a frame for longitudinal movement thereof; and a slide slidably mounted to the slide support for up and down movement along the slide support, the slide including: a body arranged to move along the slide support; and a coupling device slidably mounted to the slide for transverse movement toward and away from the slide support, wherein, in operation, the empty pallet is secured by the coupling device and picked up and moved to the pallet storage position.

[0028] In one embodiment, the engagement device comprises one of: a wedge-shaped clamp having jaws that engage a portion of the pallet; a vacuum gripper that engages the pallet by suction; and a clamp gripper having jaws that clamp around the pallet.

[0029] In one embodiment, the pallet ejection robot operates to lift the empty pallet above an adjacent block package and transport the empty pallet to the rear of the base where it is placed on pallet rests arranged between opposing side frames of the base.

[0030] In one embodiment, the at least one transfer robot includes: a column support slidably mounted to a frame for longitudinal movement thereof; a beam slidably mounted to the column support at one end for up and down movement along the column support; a slide slidably mounted to the beam for transverse movement along the beam; and an arm slidably mounted to the slide for up and down movement, wherein the distal end of the arm includes a gripping mechanism for picking up blocks.

[0031] In one embodiment, the robotic block laying machine further comprises a shuttle sorting system configured to store shuttles in the base, the shuttle sorting system comprising: a shuttle storage area comprising multiple layers of tracks on which the shuttles travel and are stored when not in use; a device for moving the shuttles to different layers of tracks in the storage area; and a shuttle translator configured to move the shuttles into and out of the shuttle storage area.

[0032] In one embodiment, the at least one transfer robot places blocks into a shuttle disposed on a top track of the shuttle storage area.

[0033] In one embodiment, the top track is used by a departing shuttle loaded with blocks, and the middle and bottom tracks are used by a returning empty shuttle or a malfunctioning shuttle.

[0034] In one embodiment, the shuttle device sorting system includes a shuttle device elevator configured to move the shuttle devices arranged thereon to different levels of tracks in the storage area.

[0035] In one embodiment, the shuttle translator is located adjacent the shuttle elevator.

[0036] In one embodiment, the shuttle device sorting system includes a first and a second shuttle device elevator located at opposite ends of the track of the storage area, and the first and second shuttle device elevators are configured to move the shuttle devices arranged thereon to different levels of the track of the storage area.

[0037] In one embodiment, the first shuttle elevator travels between the bottom track and the middle track of the shuttle storage area, and the second shuttle elevator travels between the top, middle, and bottom tracks.

[0038] In one embodiment, the robotic block laying machine further comprises a turntable concentrically aligned with the boom slew ring at the bottom of the tower, the turntable being rotatable about the tower and comprising a plurality of radially spaced turntable rotators, each of the turntable rotators being provided with two pairs of tracks configured to: receive loaded shuttles from the shuttle translator and travel the loaded shuttles to the tower track segments; and receive empty shuttles from the tower track segments and travel the empty shuttles to the shuttle translator.

[0039] In one embodiment, each of the turntable rotators includes first and second spaced-apart turntable rotator track segments, and each of the turntable rotators is configured to rotate from a first position in which the rotator track is aligned with the shuttle translator track segment to a second position in which the rotator track is aligned with the tower track segment.

[0040] In one embodiment, the carousel has three carousel rotators for storing shuttles with required blocks in a block laying sequence.

[0041] In one embodiment, in use, the shuttle translator is moved laterally from the shuttle storage area to the turntable, while the turntable is rotated to align one of the turntable rotators with the translator to receive the shuttle thereon, the turntable is then rotated to position the loaded turntable rotator adjacent to the tower track segment, and the loaded turntable rotator is then rotated to align the turntable rotator track segment with the tower track segment to allow the shuttle to travel between the turntable and the tower.

[0042] In one embodiment, the turntable is powered by electrical slip rings that allow for continuous rotation.

[0043] In one embodiment, during transfer of a shuttle between the turntable rotator and the tower, the rotation of the turntable is slaved to track the swinging motion of the boom.

[0044] In one embodiment, the tower includes a boom pivot about which the proximal end of the boom pivots, and the tower further includes a tower rotator pivotally mounted to the tower for coaxial pivoting with the boom pivot, the tower rotator being used to transfer a shuttle device between the tower and the boom.

[0045] In one embodiment, the tower rotator includes a body having tower rotator track segments configured to receive a loaded shuttle device heading to the block laying robot or an empty shuttle device returning to the shuttle device storage area, and the tower rotator is configured to pivot between a first position and a second position, wherein the tower rotator track is aligned with the tower track segments to align with the tower transfer shuttle device, and the tower rotator track segments are aligned with the boom track segments to align with the boom transfer shuttle device.

[0046] In one embodiment, during the transition shuttling between the tower rotator and boom, the pivoting motion of the tower rotator is slaved to the lifting angle of the boom.

[0047] In one embodiment, the boom includes two pairs of telescopic boom members and rod members with at least one pivot joint therebetween, and each member includes a track segment extending substantially along the length of each member, the track segments being configured to allow a shuttle device to travel along the boom.

[0048] In one embodiment, each boom or rod track segment includes two layers of inner track, including a first track and a lower track, wherein a loaded shuttle device travels on the first track to the block-laying robot of the robotic block laying machine, and an empty shuttle device returns to the base of the block-laying robot on the lower track.

[0049] In one embodiment, the end effector of the block laying robot includes an upper track and a lower track, configured to transfer the shuttle device from the lower track to the upper track after the block is laid.

[0050] In one embodiment, a loaded shuttle is driven to the lower track of the end effector and an empty shuttle is driven in the opposite direction from the upper track of the end effector to exchange shuttles between the boom and the end effector.

[0051] In one embodiment, the shuttle devices are exchanged simultaneously.

[0052] In one embodiment, the shuttle is exchanged between the boom and the end effector by a shuttle rotator disposed between the boom and the lay arm, the shuttle rotator rotating the shuttle 180 degrees.

[0053] In one embodiment, the block-laying robot is part of a laying head comprising a support tower pivotally connected to a distal end of the boom, and the block-laying robot is suspended from the support tower.

[0054] In one embodiment, the support tower of the laying head comprises a U-shaped body having a pair of arms, the U-shaped body being pivotally mounted by the arms for controlled rotation relative to the distal end of the boom, and the shuttle rotator being mounted to the support tower.

[0055] In one embodiment, the shuttle rotator includes an upper track and a lower track, and the loaded shuttle traveling along the upper track of the boom travels to the upper track of the shuttle rotator, and the shuttle rotator rotates 180 degrees to flip the loaded shuttle, thereby causing it to travel to the lower track of the end effector with the blocks in a downward laying posture.

[0056] In one embodiment, the block laying robot is a spherical geometry robot, the laying arm extends linearly in a radial direction and is rotationally controllable in roll and pitch directions via a support tower joint, and the end effector is controllable in roll, pitch and yaw directions via a wrist joint.

[0057] In one embodiment, the robotic block laying machine further comprises an adhesive application system configured to be supported proximate to the block laying robot, comprising: at least one adhesive tank; a nozzle outlet configured to spray adhesive onto a lower surface of a block; a supply line extending from the at least one adhesive tank to the nozzle outlet; and a motor-driven gear pump that pumps the adhesive through the supply line.

[0058] In one embodiment, adhesive is sprayed onto the blocks as the shuttle travels past the nozzle outlet.

[0059] In one embodiment, the robotic block laying machine further comprises an outrigger system for stabilising the vehicle during operation, the outrigger system depending from the support frame and comprising front folding legs arranged on opposite sides of the vehicle, the folding legs being pivotally connected to foot pads and, in use, the legs being deployed at an angle to the ground.

[0060] In one embodiment, the front folding legs are inclined forward.

[0061] In one embodiment, the outer ends of the front folding legs are lower.

[0062] In one embodiment, in use, the front folding legs are deployed on the building side of the vehicle.

[0063] In one embodiment, the outrigger system further comprises front jacks, each having an upright plunger, the front jacks being mounted adjacent the folding legs on opposite sides of the vehicle for use on the road side of the vehicle.

[0064] In one embodiment, the outrigger system further comprises rear extension legs on opposite sides of the vehicle, each of the rear extension legs having an upright plunger deployable in any extended position of the leg.

[0065] In one embodiment, the vehicle further comprises an onboard generator capable of operating in a generator mode or a motor mode, wherein the generator is driven by the diesel engine of the vehicle via a power take-off (PTO) and a drive shaft.

[0066] In one embodiment, the electrical system of the machine is powered by one of the generator or shore power.

[0067] In one embodiment, the robotic block laying machine includes a hydraulic system including a hydraulic pump driven by the vehicle's diesel engine or the generator in motor mode.

[0068] In one embodiment, the vehicle comprises one of: a rigid body truck; a semi-trailer for attachment to a tractor; and a trailer.

[0069] In an embodiment, the masonry unit is one of: a brick or block for use in building walls; a tile for use in building roofs; and a paving block for use in building exterior floors.

[0070] In another broad form, one aspect of the present invention is directed to a vehicle including a robotic block laying machine for constructing a block structure, the vehicle comprising: a vehicle chassis; a support frame mounted to the chassis; and a robotic block laying machine mounted from the support frame, the robotic block laying machine comprising: a base; a boom extending from the base; and a plurality of shuttles, each of which is configured to: receive blocks; and travel along the boom to transport blocks along the boom; and a block laying robot disposed at a distal end of the boom, wherein the block laying robot is configured to: receive the shuttle from the boom; and position the shuttle proximate a block laying location so that the shuttle can release the blocks for laying.

[0071] 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 different broad forms is not intended to be limiting. In addition, it should be understood that the features of the method can be performed using a system or device, and the features of a system or device can be implemented using a method. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] Various examples and embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

[0073] Figure 1A is a schematic perspective view of an example of a vehicle including a robotic block laying machine in a transport configuration;

[0074] Figure 1B for Figure 1A a schematic perspective view of a vehicle in a deployed configuration constructing a building wall;

[0075] Figure 1C for Figure 1B a schematic rear perspective view of the vehicle in the medium deployed configuration;

[0076] Figure 1D for Figure 1B Another schematic rear perspective view of the vehicle showing the transfer robot picking up blocks from a pallet;

[0077] Figure 1E for Figure 1B a schematic perspective view of the interior of the vehicle base showing the transfer robot loading blocks onto the shuttle;

[0078] Figure 1F for Figure 1B a schematic perspective view of the interior of the vehicle base showing the shuttle device on the turntable adjacent to the tower;

[0079] Figure 1G for Figure 1B A schematic perspective view of the machine showing the shuttle moving along the boom toward the block-laying robot;

[0080] Figure 2 for Figure 1A A schematic perspective view of a truck chassis used in a vehicle;

[0081] Figure 3A for Figure 1A A schematic perspective view of the bottom side of the support frame of the vehicle;

[0082] Figure 3B for Figure 3A Top view of the middle support frame;

[0083] Figure 3C for Figure 3A a schematic perspective view of the center support frame with skin panels and doors installed;

[0084] Figure 4A for Figure 1B a schematic perspective view of a vehicle showing a jack deployed on the road side of the vehicle;

[0085] Figure 4B for Figure 4A Detailed schematic perspective view of the rear legs and jack shown in FIG;

[0086] Figure 4C for Figure 4A a schematic perspective view of a vehicle showing the legs deployed on the building side of the vehicle;

[0087] Figure 5A is a schematic perspective view of a bag conveyor;

[0088] Figure 5B is a schematic top view of a series of package conveyors;

[0089] Figure 5C is a detailed schematic perspective view of a transition section between adjacent bag conveyors;

[0090] Figure 5D To show the installation Figure 1B a rear schematic perspective view of a bag conveyor within a base of a vehicle;

[0091] Figure 6A is a schematic perspective view of a tray ejector;

[0092] Figure 6B for Figure 6A a schematic rear perspective view of the center tray ejector;

[0093] Figure 6C for Figure 6A A detailed schematic perspective view of the middle tray ejector;

[0094] Figure 6D for Figure 6ASchematic front view of the middle tray ejector;

[0095] Figure 6E To show the installation Figure 1B Inside the vehicle's base Figure 6A a schematic rear perspective view of the center tray ejector;

[0096] Figure 6F for Figure 6A a schematic perspective view of a mid-tray ejector holding an empty tray in operation;

[0097] Figure 6G for Figure 6A A schematic perspective view of a mid-tray ejector lifting an empty pallet;

[0098] Figure 7A A schematic perspective view of a transfer robot;

[0099] Figure 7B for Figure 7A Another schematic perspective view of the transfer robot;

[0100] Figure 7C for Figure 7A A schematic perspective view of the transfer robot in an elevated position;

[0101] Figure 7D for Figure 7A A detailed schematic perspective view of a gripper assembly of a transfer robot arm of a transfer robot;

[0102] Figure 7E A schematic perspective view of a transfer robot arm;

[0103] Figure 7F is another schematic perspective view of a transfer robot arm;

[0104] Figure 7G for Figure 1B A schematic perspective view of two transfer robots operating within a base of a vehicle;

[0105] Figure 7H To transfer the robot, place the blocks into Figure 1B A schematic perspective view of a saw module within a base of a vehicle;

[0106] Figure 8A is a schematic perspective view of an example of a shuttle device for transporting blocks through a machine;

[0107] Figure 8B for Figure 8A A schematic perspective view of the middle shuttle device holding the building blocks;

[0108] Figure 8C for Figure 8ASchematic side view of the shuttle mechanism;

[0109] Figure 8D for Figure 8A Schematic top view of the shuttle device;

[0110] Figure 8E for Figure 8A a schematic bottom view of the middle shuttle device;

[0111] Figure 8F for Figure 8A a detailed schematic perspective view of the middle shuttle, showing the drive assembly;

[0112] Figure 8G for Figure 8A a detailed schematic perspective view of the mid-shuttle, showing the front wheel assembly;

[0113] Figure 8H for Figure 8A A schematic perspective view of the front wheel assembly of the middle shuttle device;

[0114] Figure 8I for Figure 8A A schematic perspective view of a clamp assembly of a shuttle device;

[0115] Figure 8J for Figure 8I a schematic bottom perspective view of the middle clamp assembly;

[0116] Figure 8K for Figure 8A a schematic perspective view of the shuttle assembly with the clamp assembly in an offset position;

[0117] Figure 8L for Figure 8K a schematic bottom perspective view of the middle shuttle device;

[0118] Figure 9A A schematic perspective view of a shuttle device sequencing system;

[0119] Figure 9B for Figure 9A A schematic perspective view of a rear shuttle elevator of a middle shuttle sequencing system;

[0120] Figure 9C for Figure 9A a schematic perspective view of a front shuttle elevator of a middle shuttle sequencing system;

[0121] Figure 9D for Figure 9A A schematic perspective view of a shuttle translator of a shuttle sequencing system;

[0122] Figure 9E for Figure 9DSchematic side view of the mid-shuttle translator;

[0123] Figure 9F for Figure 9D a schematic rear perspective view of the mid-shuttle translator;

[0124] Figure 9G for Figure 9A A schematic rear perspective view of the shuttle storage area of ​​the shuttle sequencing system;

[0125] Figure 9H for Figure 9G a schematic side view of the mid-shuttle storage area;

[0126] Figure 9I for Figure 9G Schematic rear view of the mid-shuttle storage area;

[0127] Figure 9J for Figure 9G a detailed schematic perspective view of the storage area of ​​the middle shuttle;

[0128] Figure 9K A schematic perspective view of the alignment of the shuttle translator and the turntable;

[0129] Figure 9L is a schematic perspective view of a shuttle device being driven from a shuttle device translator to a turntable rotator;

[0130] Figure 10A is a schematic three-dimensional diagram of a turntable;

[0131] Figure 10B for Figure 10A a schematic bottom-up perspective view of the center turntable;

[0132] Figure 10C is a schematic perspective view of a shuttle device for loading building blocks in a turntable rotator on a turntable;

[0133] Figure 10D is a schematic perspective view of the turntable rotator aligned with the tower track on the tower;

[0134] Figure 11A is a schematic perspective view of a tower;

[0135] Figure 11B for Figure 11A Another schematic perspective view of the middle tower;

[0136] Figure 11C is a schematic perspective view of a shuttle device on a tower track adjacent to a tower rotator;

[0137] Figure 11D is a schematic perspective view of a shuttle device rotating in a tower rotator;

[0138] Figure 11E A schematic perspective view of the tower rotator rotating to align with the boom;

[0139] Figure 12A for Figure 1A A schematic side view of the boom system of the vehicle;

[0140] Figure 12B for Figure 1A A schematic perspective view of a boom system of a vehicle;

[0141] Figure 12C for Figure 1A Another schematic perspective view of the boom system of the vehicle;

[0142] Figure 13A for Figure 12A a schematic perspective view of a first boom element of a mid-boom system;

[0143] Figure 13B for Figure 13A Another schematic perspective view of the first movable arm element;

[0144] Figure 13C for Figure 13A A schematic front view of the first boom element;

[0145] Figure 13D for Figure 13A A detailed schematic perspective view of the proximal end of the first movable arm element;

[0146] Figure 13E for Figure 13A A detailed schematic perspective view of the distal end of the first movable arm element;

[0147] Figure 14A for Figure 12A a schematic perspective view of a second boom element of the mid-boom system;

[0148] Figure 14B for Figure 14A A detailed schematic perspective view of the proximal end of the second movable arm member;

[0149] Figure 14C for Figure 14A a detailed schematic perspective view of the distal end of the second boom element;

[0150] Figure 14D for Figure 14A another detailed schematic perspective view of the distal end of the second boom member, showing the shuttle traveling along its top track;

[0151] Figure 14E for Figure 14Aanother detailed schematic perspective view of the distal end of the second boom member, showing the shuttle traveling along its top track;

[0152] Figure 14F for Figure 14A A schematic rear view of the second boom element;

[0153] Figure 14G for Figure 14A another schematic rear view of the second boom element showing a loaded shuttle on the top track and an empty shuttle on the bottom track;

[0154] Figure 14H for Figure 14A Another detailed schematic perspective view of the proximal end of the second movable arm member;

[0155] Figure 14I is a schematic perspective view of a luffing rotator;

[0156] Figure 15A for Figure 12A a schematic perspective view of a first rod element of a mid-boom system;

[0157] Figure 15B for Figure 15A a detailed schematic bottom perspective view of the proximal end of the first rod element;

[0158] Figure 15C is a detailed schematic perspective view of the luffing joint between the second boom element and the first mast element in a folded configuration;

[0159] Figure 15D for Figure 15A A schematic perspective view of the distal end of the first rod element;

[0160] Figure 16A for Figure 12A a schematic perspective view of a second rod element of the mid-boom system;

[0161] Figure 16B for Figure 16A A detailed schematic perspective view of the proximal end of the second rod element;

[0162] Figure 16C for Figure 16A A detailed schematic perspective view of the distal end of the second rod element;

[0163] Figure 17A for Figure 1B A schematic perspective view of the laying head of the vehicle;

[0164] Figure 17B for Figure 17A Schematic top view of the middle laying head;

[0165] Figure 17C for Figure 17A a detailed schematic perspective view of the bottom of the support tower of the middle laying head;

[0166] Figure 17D for Figure 17A Another detailed schematic perspective view of the bottom of the support tower of the middle laying head;

[0167] Figure 17E for Figure 17A a detailed schematic bottom perspective view of the center laying head showing the track segment associated therewith;

[0168] Figure 17F for Figure 17A a schematic perspective view of the upper side of the middle laying head;

[0169] Figure 17G for Figure 17A A schematic perspective view of the shuttle device rotator of the middle laying head;

[0170] Figure 17H for Figure 17A A schematic perspective view of a block laying robot with a middle laying head;

[0171] Figure 17I for Figure 17H Another schematic perspective view of the middle block laying robot;

[0172] Figure 17J for Figure 17H A schematic perspective view of a laying wrist of a block laying robot;

[0173] Figure 17K for Figure 17H Another schematic perspective view of the laying wrist of the block laying robot;

[0174] Figure 17L for Figure 17H A schematic perspective view of the end effector of the block laying robot;

[0175] Figure 17M for Figure 17L a schematic rear perspective view of the middle end effector;

[0176] Figure 18A To constitute Figure 17A A schematic perspective view of an adhesive application system of a portion of a placement head;

[0177] Figure 18B for Figure 18A Another schematic perspective view of the adhesive application system;

[0178] Figure 18C for Figure 18A a schematic front view of the adhesive application system;

[0179] Figure 19A for Figure 1A A schematic perspective view of a saw module of a vehicle;

[0180] Figure 19B for Figure 19A Another schematic perspective view of the saw module;

[0181] Figure 19C for Figure 19A Schematic perspective view of the mid-saw module, with some skin panels removed for clarity;

[0182] Figure 19D for Figure 19A Another schematic perspective view of the mid-saw module with some skin panels removed for clarity;

[0183] Figure 19E for Figure 19A A schematic perspective view of a first block translator of a middle saw module;

[0184] Figure 19F for Figure 19E A schematic top view of the first block translator;

[0185] Figure 19G for Figure 19A A schematic perspective view of the block turning mechanism of the middle saw module;

[0186] Figure 19H for Figure 19G Another schematic perspective view of the middle block turning mechanism;

[0187] Figure 19I is a schematic perspective view of the second block translator in use, showing the second block translator pushing the block toward the fence of the saw module as the block is cut;

[0188] Figure 20 is a schematic diagram of an example of a control system for controlling a fleet of shuttles used in a robotic block laying machine;

[0189] Figure 21 A schematic diagram of an example control system for controlling a robotic block-laying machine. DETAILED DESCRIPTION

[0190] Now combine Figures 1A to 1G An example of a vehicle 1 including a robotic block laying machine 20 for building a block structure is described.

[0191] As used herein, the term "block" refers to a piece of material, typically in the form of a polyhedron, such as a cuboid having six quadrilateral, more typically substantially rectangular, faces. Blocks are typically made of a hard material and may contain openings or recesses, such as cavities, etc. Blocks are configured to be used to construct structures such as buildings. Specific examples of blocks include bricks, besser blocks, concrete blocks, etc. The term "block" should also include other integral solid building elements, such as tiles for building roofs and paving stones for building exterior floors. Although the following description uses block walling as an example, it should be understood that other building elements, such as tiles and paving stones, can also be transported by the machine.

[0192] In this example, vehicle 1 includes a vehicle chassis 2, a support frame 10 mounted to chassis 2, and a robotic block laying machine 20 mounted from support frame 10. Support frame 10 is generally a frame that structurally supports machine 20 and may include a base frame and side frame components for supporting the various components of machine 20. Support frame 10 may also include skin panels that substantially cover the machine and help protect the internal components of the machine from rain, wind, dust, sunlight, and other environmental factors. Skin panels also provide protection from hazardous human contact. In one example, support frame 10 is a large welded component consisting of three main components (a base frame and opposing side frames) that are machined and then welded together to form a single unit. In completely knocked-down (CKD) form for global transportation, it can be manufactured into smaller components that are bolted together to fit into a container. However, in driveaway form, it is more efficient to construct it as a single welded structure.

[0193] The vehicle 1 is typically in the form of a rigid-body truck, which provides the robotic block laying machine 20 with mobility and allows it to be driven on roads to and from construction sites. In some examples, the vehicle 10 is an 8×8, 8×6, or 8×4 rigid-body truck, such as those manufactured by Mack, Volvo, Mercedes, Iveco, MAN, Isuzu, or Hino. The truck has a typical driver's cab. In an alternative configuration, a semitrailer connected to a prime mover via a fifth wheel can be used in place of the rigid-body truck. Alternatively, the vehicle can include a trailer. In one example, the vehicle is an 8×4 Isuzu FYJ-350XLWB, which has a wheelbase long enough to provide ample space for the machine components to be arranged and easily accessible. In another example, the vehicle is a Mack TerraPro.

[0194] The aforementioned vehicle can be used to support and transport the robotic block laying machine, and thus the robotic block laying machine can be designed to be integrated with the vehicle. However, as will be understood below, this is not a requirement, and the robotic block laying machine described in detail below can also be separated from the vehicle. For example, the robotic block laying machine can be installed in a container or other similar structure and transported to the construction site via a separate vehicle, whereupon the robotic block laying machine can be installed at the site and used as needed. Therefore, in the following description, references to "vehicle" should be understood as an embodiment in which the robotic block laying machine is integrated into the vehicle, and this should not be considered as the required or only possible implementation, and references to the vehicle should not be considered restrictive.

[0195] The robotic block laying machine 20 includes a base 5 that can accommodate blocks, such as a block package 6. The base 5 also includes at least one transfer robot 60 that is configured to pick individual blocks, such as directly from the block package 6. The base of the machine is typically the area of ​​the machine located above the truck bed, and the transfer robot 60 is defined as a robot located within the machine base that interacts with the blocks, such as picking blocks from the block package and transferring blocks between other blocks within the base.

[0196] Machine 20 also includes a boom system comprising a boom 30, which may include a plurality of telescopic booms 32, 34 and rods 36, 38 with at least one pivot joint 35 therebetween, although other suitable arrangements may also be used. A tower 31 is rotatably mounted in base 5 about a boom axis of rotation, supporting boom 30, and pivotally connected to tower 31. A block-laying robot 40 (optionally forming part of a laying head) may be mounted at the distal end of the boom for laying blocks delivered by boom 30. In the illustrated example, boom 30 has four elements, including two booms and two rods, and has an operating radius of 32 meters, allowing it to be operated up to the height of a three-story building, although it will be appreciated that other configurations may be used. In other examples, the operating radius when the boom is fully extended may be one of 24-25 meters, 25-26 meters, 26-27 meters, 27-28 meters, 28-29 meters, 29-30 meters, 30-31 meters, and 31-32 meters.

[0197] A plurality of shuttles 50 are provided, which are optionally storable in the base 5. Each shuttle 50 is configured to receive blocks from at least one transfer robot 60 and transport the blocks along the boom system from the base 5 to the block-laying robot 40. In one example, the shuttles move inside the boom, although this is not required and, alternatively, the shuttles may move along the outside of the boom.

[0198] Thus, the shuttle device acts as a transport vehicle, continuously transporting blocks through the system. A single shuttle device can transport blocks from the base of the robotic block-laying machine to the block-laying robot without transferring the blocks to any other mechanism. To achieve this, the shuttle device can be configured to grip the blocks during transport, then release them and release them onto the wall under construction. As a result, the number of block handovers within the machine is significantly reduced, improving the overall reliability of the machine. In an alternative arrangement, the block-laying robot can include a gripper that grips the blocks received from the shuttle device at the laying head.

[0199] In one example, the shuttles travel along a semi-continuous path through the machine, with a loaded transport shuttle traveling from the base to the block-laying robot and an empty return shuttle returning from the block-laying robot to the base. The shuttles typically travel on tracks distributed throughout the machine. The tracks may be static (i.e., fixed) track segments or movable track segments (e.g., in the form of elevators, translators, or rotators). The shuttles may have an independent power source, such as a battery, or the tracks may be powered and provide power to the shuttles.

[0200] In one example, the shuttles are semi-autonomous, with their own logic, sensors, actuators, battery power, battery management and charging, wireless communications, and drive systems. A central machine controller or dedicated shuttle fleet controller typically coordinates the movement of the shuttles, with individual shuttles controlling their own functions. In some examples, a machine may include twenty (20) to thirty (30) shuttles to achieve a target lay rate exceeding 350 blocks per hour.

[0201] Several further features will now be described.

[0202] As described above, the base can be configured to receive one or more packages of blocks, and at least one transfer robot is configured to pick one of the blocks from the packages. In this example, the packages are typically arranged in a single file within the machine's base at designated packing stations. The machine base allows for packages up to 1200 mm wide to accommodate large blocks up to 600 mm in length and 300 mm in width. In contrast, earlier machines from the applicant can accommodate packages up to 1000 mm wide. The blocks are loaded into the machine from the back of a truck. In some examples, the packages are placed on wooden (or other material) pallets, with the blocks stacked on the pallets. The packages are fed into the machine onto a pack conveyor module, which moves the packages forward to an empty packing station. In the illustrated example, there are at least three pack conveyors, although other machine configurations can accommodate up to five. Therefore, the machine is designed to accommodate at least three and at most five packages of blocks during use. Typically, only three pack conveyors are implemented if the machine additionally includes a saw module.

[0203] In one example, each bag conveyor module is a chain conveyor, comprising a base frame and a drive assembly comprising multiple chains extending along the length of the base frame between a pair of shafts and spaced apart along the width of the base frame. The chains are driven by a motor connected to one of the shafts. Using multiple chains per bag conveyor module eliminates the need for custom rollers for the conveyor and provides smoother movement for block bags not placed on pallets.

[0204] Different types of blocks can be loaded into the machine simultaneously and consumed at different rates. This means the leading block pack may be exhausted first, necessitating the removal of the pallet so that the next pack can be moved forward. Therefore, the pack conveyor is designed as a segmented structure slightly longer than a single pack. Each module has independent electronic controls, allowing each module to be tested individually and replaced as a line-replaceable unit (LRU).

[0205] As blocks arrive stacked on pallets, the empty pallets are typically removed from the pack conveyor module by a pallet ejection robot that picks up the empty pallet and moves it to a pallet storage location for retrieval from the base and / or vehicle. In one example, the pallet ejection robot may be operable to lift the empty pallet above an adjacent pack of blocks and transport it to the rear of the base and / or vehicle where it is placed on a pallet tray disposed between opposing side frames of the base and / or vehicle.

[0206] In one example, a pallet ejection robot includes a carriage support slidably mounted to a frame, such as a side frame of a vehicle or a base, for longitudinal travel thereof; and a carriage slidably mounted to the carriage support for travel up and down, such as in a vertical or substantially vertical direction, along the carriage support. The carriage includes a body arranged to travel along the carriage support; and an engagement device slidably mounted to the carriage for transverse travel toward and away from the carriage support, wherein an empty pallet is secured by the engagement device and picked up and moved to a pallet storage location.

[0207] Different pallet configurations may require different engagement devices to pick up the pallet. In one example, the engagement device is a wedge-shaped clamp with jaws that engage a portion of the pallet, while in another example, the engagement device is a vacuum gripper that engages the pallet through suction. Alternatively, a clamp gripper with jaws that grip around the pallet may be provided.

[0208] Pallet ejection robots, typically Cartesian robots with linear motion in X, Y, and / or Z, are used to pick up empty pallets and move them to an empty pallet storage station. They must be able to maneuver empty pallets around full block packages. High-speed laying and the large blocks used result in fast pallet turnover. Block packages are delivered by telehandlers, which also remove empty pallets. To reduce telehandler cycle times, it's ideal to stack empty pallets so the telehandler can remove a stack of empty pallets instead of individual ones.

[0209] As previously mentioned, the machine comprises at least one transfer robot configured to pick up individual blocks directly from a pack of blocks.

[0210] The transfer robot picks blocks from the block bag and loads them into the shuttle device, or places the blocks into the saw (if a saw module is included). The transfer robot also picks blocks from the saw and loads them into the shuttle device. The transfer robot is equipped with a vision system to detect the position of the blocks in the block bag. In one example, the transfer robot has the highest cycle time of all modules and may become a key driver of the speed of the production process due to the frequent movements required to complete the task. Therefore, to improve productivity and avoid bottlenecks, it is preferred to have two transfer robots. The independent and continuous shuttle device arrangement facilitates the parallel operation of the transfer robots by allowing each transfer robot to load the shuttle device simultaneously. To avoid collisions, physical stops and proximity sensors are installed between the transfer robots to detect each other and prevent them from approaching each other and causing collisions. They may also have software interlocks and / or logic to prevent collisions.

[0211] The main motion of the transfer robot uses linear orthogonal (Cartesian) axes, which provide consistent dynamic characteristics and support fast motion without kinematic transformation. To achieve the required Z-axis (i.e. vertical direction) motion, the Z-axis is telescopic in one example.

[0212] In one example, the transfer robot includes a column support slidably mounted to a frame, such as a side frame of a vehicle and / or a base, for longitudinal travel thereof; a beam slidably mounted at one end to the column support for upward and downward travel, such as in a vertical or substantially vertical direction, along the column support; a carriage slidably mounted to the beam for lateral movement along the beam; and an arm slidably mounted to the carriage for vertical movement up and down, the distal end of the arm including a gripping mechanism for picking up a block from a bag of blocks.

[0213] Typically, the gripping mechanism includes a pair of gripping fingers configured to grasp the inner core of a block. The gripping fingers are driven open and closed by a linear actuator, such as a gear and rack. The gripping mechanism includes a body rotatable about a rotation axis aligned with the longitudinal axis of the arm, enabling the arm to rotate the block held by the gripping fingers. In other arrangements, the gripper may be a vacuum gripper configured to pick up a block (e.g., a coreless block) by applying suction to the block's surface.

[0214] As previously mentioned, in one example, the arm is telescopic. Typically, a telescopic arm comprises a first arm element and a second arm element, the second arm element being slidable relative to the first arm element along a track mounted to the first arm element. The first and second arm elements are slidably connected by a belt driven by a pulley connected to the first arm element, which is clamped to the second arm element. In this example, the first arm element is driven up and down relative to the carriage via a rack and pinion drive, with movement of the first arm element causing the second arm element to synchronously telescope relative to it. However, it should be understood that other arrangements, such as a linear actuator, may be used.

[0215] To locate blocks on a block pack for easy picking, the transfer robot typically includes a beam-mounted vision system for imaging the blocks on the block pack, and one or more light sources to provide uniform illumination of the blocks. Preferably, the one or more light sources include a flash lamp that can be brighter than sunlight and any other ambient light. The flash lamp provides illumination that is at least, and preferably, two orders of magnitude, higher than sunlight to ensure sufficient contrast for the vision system to detect block edges. In other words, the flash lamp unit is approximately 10 to 100 times brighter than sunlight. In one example, the flash lamp is an ultra-bright xenon flash lamp.

[0216] In one example, the illuminated surface area is approximately 450x700mm, with an irradiance of 2000W / m at a surface distance of 600mm. 2 Typically, the spectral band of a flash unit is in the 400-800nm ​​range, which is consistent with the quantum efficiency of cameras used in vision systems, such as the JAIGOX-12401M-PGE machine vision camera.

[0217] Typically, each flash delivers 120 joules of light, with flash duration adjustable from 0.01ms to 1ms and flash intensity variation of less than 5%.

[0218] Each flash unit typically has a driver configured to trigger a flash when the corresponding camera captures an image.

[0219] In one arrangement, the vision system includes three cameras spaced along the length of the beam to provide adequate viewing of the block pack in all operating configurations. Typically, each camera has an associated flash unit. However, other positioning mechanisms may be used, such as a single vision system combined with fiducial markers, LiDAR, or other suitable devices.

[0220] In general, a vision system for imaging a building block package exposed to variable ambient light, including sunlight, uses an edge detection algorithm to identify building blocks in the captured images. The vision system includes: a plurality of cameras positioned above the building block package, each camera configured to acquire an image; a plurality of flash units, each associated with a corresponding camera and controlled to trigger a flash when the camera captures an image, the flash configured to be one and preferably two orders of magnitude brighter than sunlight; and image processing software for stitching each acquired image into a composite image of the building block package and identifying one or more building blocks in the composite image.

[0221] As previously mentioned, in one example, two transfer robots, designed to pick individual blocks directly from a pack, are located in a base and work simultaneously to continuously feed blocks into a shuttle for delivery to a block-laying robot at the end of a boom. In operation, each transfer robot places a block picked from a pack into an empty shuttle or saw module (if used) waiting in the base. The transfer robots can then place blocks into the saw and retrieve cut blocks from the saw into an empty shuttle.

[0222] A shuttle sequencing system can be located in the base of the machine, providing a location for storing and loading shuttles. This allows for the order of the shuttles to be sorted and, optionally, for charging the shuttle batteries. It also sorts the shuttles to and from the turntable that rotates around the tower. The shuttle sequencing system also provides a location for a transfer robot to load blocks onto the shuttles.

[0223] In one example, the shuttle sequencing system includes a shuttle storage area that includes multiple levels of track on which shuttles travel and are stored when not in use. In the example shown, the shuttle storage area has three levels of track, accommodating up to thirty (30) shuttles in total. The shuttles can be charged at any location within the shuttle storage area, with the charging track separate from the motion track.

[0224] The shuttle arrangement system may further include a device for moving the shuttle to different levels of track in the storage area, such as an elevator, a track loop, etc., depending on the preferred implementation. A shuttle translator may also be provided, configured to move the shuttle into and out of the shuttle storage area.

[0225] In one example, the shuttle storage area has a rear section, a middle section that opens like a door, and a front section. The openable middle section allows the shuttle to be removed or added, or to be maintained outside the machine.

[0226] Typically, the transfer robot loads the shuttles on the top track of the storage area. The shuttle on the top track is the departure shuttle, traveling from the rear of the machine to the front. The middle and bottom tracks are used by empty return shuttles, traveling in the opposite direction, from the front to the rear of the machine. This three-level track setup also provides redundancy for the system: a faulty shuttle can be stored on one level, while the remaining two levels supply and return functioning shuttles.

[0227] The shuttle sorting system also includes a shuttle elevator configured to move a shuttle disposed thereon to different levels of track in the storage area. In one example, the sorting system includes first and second shuttle elevators, respectively located at the front and rear of the shuttle storage area (between opposite ends of the track), configured to lift the shuttle disposed thereon to different levels of track in the storage area. A shuttle translator is located adjacent to the elevators, in one example, located next to the front elevator, and is operable to move the shuttle into and out of the shuttle storage area.

[0228] The first shuttle elevator travels between the bottom and middle tracks of the shuttle storage area, while the second shuttle elevator travels between the top, middle, and bottom tracks. This difference in travel is accommodated by assembling blocks in the appropriate locations and setting the module's software configuration. It should also be noted that alternative specialized shuttles (such as gable-cutting shuttles or mortar-carrying shuttles) can be stored and sequenced by the elevator.

[0229] In one example, each shuttle lift includes a lift frame connected to a frame (e.g., a side frame of a vehicle and / or a base), and a lift tray slidably connected to the lift frame for vertical travel up and down the frame, the lift tray including a body having lift track segments engageable with shuttle wheels. The lift tray houses a single shuttle and operates to align the lift track segments with tracks on a level of a shuttle storage area, allowing the shuttle to travel to that level of the storage area.

[0230] The shuttle translator operates to move the shuttle in a direction of travel that is orthogonal to the direction the shuttle moves in the shuttle storage area. Thus, the shuttle translator moves in a direction across the width of the vehicle and / or base (i.e., transversely) to align with the storage area track or turntable.

[0231] In one example, a shuttle translator includes a translator base mounted to a frame (e.g., a base frame of a vehicle or a pedestal), and a translator assembly slidably connected to the translator base for sliding along the translator base, wherein the translator assembly includes a body having first and second translator track segments, each track segment being engageable with a wheel of the shuttle. The track segments of the translator are orthogonal to a direction of travel of the translator.

[0232] In the first position of the shuttle translator, the first translator track segment (upper track segment) is aligned with the top track of the shuttle storage area for receiving the departure shuttle thereon. The second translator track segment (lower segment) accommodates the return shuttle. In use, the front elevator is raised so that its track segment aligns with the second translator track segment so that the return shuttle can travel from the translator to the front elevator and back to the storage area.

[0233] Because the shuttles constantly hold blocks before placing them in the wall, it's crucial that each shuttle holds the blocks in an accurate and repeatable position to minimize inaccuracies in the placement of the blocks on the wall. When the transfer robot loads the shuttles in the storage area, there can be some positional variation in the block holding position of each shuttle. To address this, a shuttle reference assembly is provided to determine the position of the blocks relative to the shuttles.

[0234] The shuttle datum assembly includes a track for receiving the shuttle and a datum plate extending transversely across the track. The datum plate is longitudinally movably mounted relative to the track so that the datum plate can be positioned at a datum plate position so that when the shuttle travels along the track to a designated position, the blocks engage the datum plate and are pushed to the datum position on the shuttle. This can thereby be used to reposition and / or align the blocks on the shuttle, ensuring that the blocks are in a known, fixed position on the shuttle, thereby helping to ensure accurate positioning of the blocks when they are laid.

[0235] In one example, the designated location is the end of the track so that the shuttle can travel to the end of the track to align / position the blocks on the shuttle.

[0236] In one example, the track of the shuttle translator is part of the shuttle translator. In this example, the shuttle translator is positioned adjacent to the shuttle translator and mounted to the translator base. The translator assembly includes a slidable arm with a translator plate mounted at its distal end. The translator plate is positioned vertically above the top track of the shuttle translator and is movable along the length of the translator track segment.

[0237] In use, when the loaded shuttle travels to the top track of the shuttle translator, the datum plate moves to a defined datum position for the specific block type, thereby datum-positioning the block. The shuttle then releases the block as it approaches the datum plate, pushing it toward the datum plate and continuing to travel until it reaches a shuttle hard stop mounted to the shuttle datum assembly frame. The shuttle then re-grips the block at the datum position.

[0238] The shuttle sequencing system also includes inductive proximity sensors located in the shuttle storage area, the first and second shuttle elevators, and the shuttle translator to confirm the presence of a shuttle at a specific location. The proximity sensors detect a trigger plate on each shuttle. Multiple trigger plates are also located along the shuttle sequencing system, which are detected by inductive proximity switches on the shuttles and used to calibrate the position of the shuttles in the system, as described in further detail below. Alternatively, an optical sensor on each shuttle detects reflective targets located along the track in the shuttle storage area, the first and second shuttle elevators, and the shuttle translator.

[0239] Typically, the second shuttle elevator includes a hard stop to which the shuttle travels, providing a reference to the shuttle's starting position.

[0240] As previously described, the base of the machine also includes a turntable positioned concentrically with the boom slew ring at the bottom of the tower, the turntable being rotatable about the tower and including a plurality of radially spaced turntable rotators, each turntable rotator being configured with two pairs of tracks to receive loaded shuttles from the shuttle translator and travel the loaded shuttles to the tower track segments, or to receive empty shuttles from the tower track segments and travel the empty shuttles to the shuttle translator.

[0241] Each turntable rotator includes first and second spaced-apart turntable rotator track segments, wherein each turntable rotator is configured to rotate from a first position in which the rotator track is aligned with the shuttle translator track segment to a second position in which the rotator track is aligned with the tower track segment.

[0242] In the example shown, the turntable has three turntable rotators that store shuttles containing, for example, cut blocks required for a block-laying sequence. It will be appreciated that a different number of turntable rotators may be provided, depending on the machine configuration and the amount of buffering / storage required to execute the block sequence. The turntable is powered via a slip ring that allows for continuous rotation, enabling it to be moved in the shortest possible direction to the next destination.

[0243] In use, the shuttle translator is moved laterally from the shuttle storage area to the turntable while the turntable rotates so that one of the turntable rotators is aligned with the translator to receive the shuttle thereon, the turntable is then rotated to position the loaded turntable rotator adjacent to the tower track segment, the loaded turntable rotator is then rotated to align the turntable rotator track segment with the tower track segment, allowing the shuttle to travel between the turntable and the tower.

[0244] The boom needs to be swiveled intermittently and almost continuously to move the block-laying robot around the construction site, so during the transfer of the shuttle between the turntable rotator and the tower, the rotation of the turntable is slaved to track the swiveling motion of the boom.

[0245] The boom slewing system supports the tower and boom, rotating them to the desired building angle. The boom slewing system uses a ball or roller bearing slewing ring with an integrated ring gear. The slewing drive is provided by two servo motors acting on a pinion gear through a bearing reducer (SpineaTwinspin). The use of two motors provides sufficient torque to resist the slewing moment generated by the wind blowing against the side of the boom. Two motors also eliminate backlash.

[0246] As previously mentioned, the tower is supported by the boom slew ring and, in turn, supports the boom. The tower includes a boom pivot, about which the proximal end of the boom pivots, and a tower rotator pivotally mounted to the tower for coaxial pivoting with the boom pivot. The main body of the tower supports tower track segments, allowing a shuttle to travel to or from the tower. The tower rotator is used to transfer the shuttle between the tower and the boom.

[0247] In one example, a tower rotator includes a body having tower rotator track segments configured to receive a loaded shuttle bound for a block laying robot or an empty shuttle returning to a shuttle storage area, and the tower rotator is configured to pivot between a first position in which the tower rotator tracks are aligned with the tower track segments for transferring the shuttle to the tower body and a second position in which the tower rotator track segments are aligned with the boom track segments for transferring the shuttle to the boom.

[0248] A hydraulic lifting cylinder for the boom is provided and mounted to the tower. The lifting cylinder changes the boom's lifting angle. During the shuttle's transfer between the tower rotator and the boom, the tower rotator's pivoting motion is driven by the boom's lifting angle.

[0249] The tower rotator is driven by an electric servo motor, which drives a pinion through a planetary gearbox. This pinion drives a gear that pivots the tower rotator. The servo motor has an integral absolute encoder and brake. A proximity switch is used to confirm the alignment of the tower rotator with the tower or first boom element. A proximity sensor detects that the shuttle is in the correct position to allow rotation.

[0250] The boom system will now be described.

[0251] The boom system includes a boom having at least two pairs of telescoping boom and rod elements with at least one pivot joint therebetween, and each element including a track segment extending substantially along the length of each element, the track segment configured to allow a shuttle device to travel along the boom.

[0252] Typically, the boom includes a hollow boom and rod element that allows the shuttle to travel inside the boom. In one specific example, each boom or rod track segment includes two layers of interior track, including a top track on which a loaded shuttle travels to the block-laying robot, and a lower track on which an empty shuttle returns to the base.

[0253] The boom includes a boom rotator located at a pivot or luffing joint between the respective boom and pole elements, the boom rotator having boom rotator track segments and configured to rotate to alternately align the boom rotator track segments with one of the adjacent boom or pole elements to transfer the shuttle device across the pivot joint.

[0254] In one example, each boom and mast element is a box-section structure comprised of a carbon fiber foam sandwich panel with aluminum or carbon fiber corner profiles bonded to the corners. The carbon fiber structure allows the boom's weight to remain within acceptable limits at an operating radius of up to 32 meters, making the boom system very light for its length and load capacity. Alternatively, the boom can be manufactured from a lightweight aluminum alloy.

[0255] The telescopic and extension motions between the respective boom and rod elements are driven by electric servomotors via chains. The pivoting, or luffing, joint between the boom and rod elements uses hydraulic cylinders to push connecting rods, providing 180 degrees of articulation. The boom has two hydraulic luffing cylinders with integrated load-holding valves. These cylinders are connected by hoses to proportional valves in the machine base. A single proportional valve spool controls the flow of oil to both cylinders, allowing the boom to articulate and extend.

[0256] As previously mentioned, the boom has internal telescoping tracks for the continuous shuttle to travel. A reciprocating boom rotator at the luffing joint moves a pair of tracks, alternately aligned with the boom or rod, to transfer the shuttle across the pivot or luffing joint. The lifting and luffing motions are achieved by hydraulic cylinders with position encoder feedback, and the telescoping motion is driven by redundant dual chains and electric servomotors. Typically, the inner tracks of the respective telescoping boom and rod elements are telescoping tracks, and the tracks of the inner boom and rod elements telescope outside the tracks of the outer boom and rod elements. In one embodiment, the tracks of the outer boom and rod elements include bosses that are configured to slidably interconnect with corresponding channels that form part of the tracks of the telescoping inner boom and rod elements.

[0257] The boom and rod elements are tubes constructed from carbon fiber foam sandwich panels, bonded at the corners with aluminum or carbon fiber corner profiles. The end fittings to the cylinders and pivot joints are steel or aluminum welded to the carbon fiber tubes.

[0258] The first boom element is mounted to the tower via welded steel bulkhead pivot fittings bonded to a composite carbon fiber tube, which in turn is bonded to machined aluminum fittings at its ends. The composite tube is constructed from four flat sandwich panels, bonded at the corners to aluminum or carbon fiber corner profiles. Ultra-high modulus pre-impregnated carbon fiber is used to achieve high stiffness at low weight. The first boom element supports a linear roller bearing block for the telescopic movement of the second boom element, which extends and retracts within it. The linear bearing block features recirculating rollers that pivot to align with the bearing steel band.

[0259] The second boom element comprises a composite carbon fiber tube bonded at its ends to welded aluminum luffing pivot fittings. The 6061-0 aluminum luffing fittings are heat treated to 6061-T6 or T4 after welding. The composite tube is constructed from four flat sandwich panels bonded at the corners to aluminum or carbon fiber corner profiles using ultra-high modulus pre-impregnated carbon fiber to achieve high stiffness at low weight.

[0260] In one example, an aluminum corner profile has a dovetail groove in which a hard steel bearing strip is captured. The shape of the corner profile simplifies the bonding process. Alternatively, if a carbon fiber corner profile is used in the corner, the steel bearing strip can be mechanically fixed to the carbon fiber.

[0261] The second boom element is telescopically moved by a chain driven by a sprocket driven by a geared electric servomotor mounted on the first boom element.

[0262] The first rod element connects to the luffing joint with a welded, post-weld heat-treated 6061-T6 aluminum fitting bonded to a composite tube. The composite tube consists of four flat sandwich panels bonded at the corners to aluminum or carbon fiber corner profiles using ultra-high modulus pre-impregnated carbon fiber for high stiffness at low weight. The fitting bonded to the tube provides a mount for the luffing cylinder and supports the luffing cylinder pin in double shear. The connecting rod above the luffing cylinder supports this fitting.

[0263] The second boom element telescopes inside the first and is also a composite tube made of four flat sandwich panels, bonded at the corners to aluminum or carbon fiber corner profiles. Ultra-high modulus pre-impregnated carbon fiber is used to achieve high stiffness at low weight. The bearing strips are installed in the same way as described for the second boom element.

[0264] The second rod element is telescopically moved by a chain driven by a sprocket driven by a geared electric servomotor mounted on the first rod element.

[0265] The block laying robot will now be described.

[0266] Typically, a block laying robot is disposed at the distal end of a boom, and includes a laying arm; and an end effector suspended from the laying arm for manipulating a shuttle device, wherein the end effector receives a loading shuttle device carrying blocks, and the laying arm moves the end effector to position the shuttle device near a block laying position, so that the shuttle device can release the blocks and thereby lay the blocks.

[0267] The end effector includes upper and lower tracks configured to transfer the shuttle from the lower track to the upper track after the blocks are laid. During use, a loaded shuttle travels to the end effector's lower track, and an empty shuttle travels in the opposite direction away from the end effector's upper track, allowing the shuttle to be exchanged between the boom and the end effector. Typically, the shuttles are exchanged simultaneously.

[0268] The shuttle is exchanged between the boom and the end effector by a shuttle rotator located between the boom and the lay arm, which rotates the shuttle 180 degrees so that the blocks are laid with the orientation facing downwards.

[0269] The end effector generally includes a frame, first and second spaced-apart end effector tracks mounted to the frame, the lower and upper end effector tracks configured to align with corresponding first and second tracks in the boom, and an elevator slidably mounted to the frame and configured to transfer an empty shuttle from the lower track to the upper track to allow a loaded shuttle to be received to the lower track and to return an empty shuttle from the upper track to the boom.

[0270] In one example, when the laying arm positions the end effector and the shuttle device thereon at the block laying position, the block is laid by releasing the block by the shuttle device. Specifically, in this case, the block laying robot is configured to receive the shuttle device from the movable arm and then position the shuttle device near the block laying position so that the shuttle device can release the block and lay the block.

[0271] Therefore, in this case, the block-laying robot is typically configured to position the end effector near the distal end of the boom to receive a loaded shuttle, position the shuttle near the block-laying location so that the shuttle can release and lay the block, and position the end effector near the distal end of the boom to return the empty shuttle to the boom. When the end effector includes a lift, the process includes receiving the loaded shuttle from the boom from the lower end effector track and then transferring the empty shuttle from the lower end effector track to the upper end effector track after the block is laid so that the shuttle can return to the boom.

[0272] The block-laying robot is typically part of a laying head comprising a support tower pivotally connected to a distal end of a boom, and the block-laying robot is suspended from the support tower.

[0273] In one example, a block-laying robot is a spherical geometry robot in which the laying arm is linearly extendable (in the radial direction) and controlled in roll and pitch by a support tower mount, while the end effector is controlled in roll, pitch, and yaw by a wrist mount. The joints of the spherical geometry robot are arranged to avoid poles and singularities within the motion envelope, meaning that the end effector can move along an arbitrary path within the envelope without any joints undergoing excessive or rapid rotation (as would be the case if there were singularities or poles within the envelope). The main pitch, roll, and linear actuators are located near the center of the sphere to minimize the inertia of the moving parts.

[0274] The block-laying robot's rotational axis is driven by a Spinea Twinspin bearing reducer driven by an electric servo motor, while the linear movement along the Z axis is driven via a toothed belt and an electric servo motor via a rack and pinion. The servo motor has an integrated brake.

[0275] In one example, the support tower and lay-up arms are carbon fiber structures with the electrical equipment housed within these structures.

[0276] Typically, the support tower includes a U-shaped body having a pair of arms by which the U-shaped member is pivotally mounted for controlled rotation relative to the distal end of the boom, and the support tower includes a shuttle rotator including upper and lower tracks, wherein a loaded shuttle traveling along the upper track of the boom travels to the upper track of the shuttle rotator, which upper track rotates 180 degrees to flip the loaded shuttle so that it can travel to the lower track of the end effector in a laying orientation with the blocks facing downward.

[0277] The inverted shuttle then travels to the lower track of the block-laying robot end effector, optionally via a fixed track segment mounted to the support tower or an auxiliary structure connected thereto.

[0278] In this arrangement, the end effector is an attachment at the end of the laying arm that is used to manipulate the shuttle to lay the blocks. In one example, the end effector includes a frame suspended from a wrist of the robotic arm, the frame having a top plate connected to the wrist, the top plate connected to opposing side plates and end plates, lower and upper tracks at least partially mounted to the opposing side plates, and an elevator slidably mounted to the frame and configured to lift an empty shuttle from the lower track to the upper track.

[0279] The elevator typically includes a crossbeam spanning the end plates and slidably mounted thereto for travel up and down the end plates, one or more lower track segments connected to the crossbeam for raising and lowering therewith, and an actuation assembly configured to move the elevator relative to the frame.

[0280] In one example, the actuation assembly includes a pneumatic cylinder and a crank connected between the cylinder piston and the crossbar, wherein the crank pivots in response to the extension and retraction of the piston to raise or lower the elevator. Pneumatic actuation is preferred because the elevator requires fast and responsive maneuvering of the shuttle device.

[0281] Additionally, during the laying motion, the pneumatic cylinder is exhausted through its rod port (via a control valve) to provide vertical compliance to the end effector, allowing the end effector to continue to descend slightly as the block contacts the surface.

[0282] It will be understood that in this example, the lower track comprises a fixed lower track segment mounted to the frame and a movable lower track segment forming part of the elevator, and the upper track comprises at least one pivotable upper track segment that can be pivoted away when the shuttle is raised from the lower track to the height of the upper track. In the raised position, the movable lower track segment is aligned with and forms part of the upper track to allow the empty shuttle to be driven away from the end effector.

[0283] In this way, the shuttles can be exchanged simultaneously at the end effector, so that when a loaded shuttle is moved in, an empty shuttle is moved out.

[0284] As the blocks travel from the shuttle rotator to the end effector, adhesive is applied to the lower surface of the blocks. In one example, this is accomplished using an adhesive application system that is configured to be supported adjacent to a block-laying robot positioned at the distal end of a boom. The adhesive application system typically includes at least one adhesive tank, a nozzle outlet configured to dispense adhesive onto the lower surface of the blocks, a supply line extending from the at least one adhesive tank to the nozzle outlet, and a motor that drives a gear pump that pumps the adhesive through the supply line. Using a motor-driven gear pump allows for a reliable supply of viscous adhesive to the nozzle and allows for measurement of the amount of adhesive applied to each block for quality control.

[0285] In one example, an adhesive application system is mounted to the laying head (specifically its support tower) and uses angled nozzle outlets to dispense adhesive to the lower surface of the blocks as they pass through the application system. Typically, the adhesive application system is mounted on each side of the support tower.

[0286] Typically, the adhesive tank is connected to a hose that feeds a gear pump via a dry-disconnect fitting, which helps prevent premature curing of the adhesive and allows the cartridge to be removed with liquid adhesive remaining in the hose and / or tank.

[0287] The nozzle outlet can be positioned on both horizontal and vertical axes to adjust the height and lateral position of the nozzle relative to the block. The nozzle is positioned on two axes (across the block and vertically) to the correct application width and height by servo motors. The vertical servo motor drives a trapezoidal threaded rod, while the horizontal servo motor drives a pinion gear that engages in a rack. The lateral position of the nozzle should be aligned with the correct rib or face shell of the block and is expected to be constant for each block type. Optionally, the lateral position can be varied as the block advances past the nozzle, thereby applying a "wavy" pattern of adhesive.

[0288] The pump motor is controlled to synchronize the dispensing of adhesive from the nozzle outlet with the movement of the shuttle carrying the blocks past the nozzle outlet.

[0289] A sensor can be used to detect the starting and ending positions of the blocks as the shuttle passes the nozzle outlet, thereby triggering the pump to dispense adhesive. Alternatively, the position of the shuttle in the machine is used to trigger the pump to dispense adhesive based on the time and distance traveled by the shuttle to and from the nozzle outlet.

[0290] Gear pumps are typically controlled to suck back a certain amount of adhesive at the end of the application cycle to reduce or minimize the amount of spillage and dripping that occurs after application.

[0291] In typical embodiments, the cartridge stores a bonding volume of approximately one of 5-6 liters, 6-7 liters, 7-8 liters, 8-9 liters, 9-10 liters, 10-11 liters, 11-12 liters, 12-13 liters, 13-14 liters, and 14-15 liters.

[0292] To achieve a repeatable adhesive signature, a fixed-displacement gear pump is used to dispense precise amounts of adhesive onto the blocks. The adhesive signature of each block can be imaged by a camera and lighting system, and the amount of adhesive dispensed can be determined by an image processor, allowing the amount of adhesive dispensed to be measured and / or verified for each block.

[0293] The shuttle device will now be described in further detail.

[0294] In one example, each shuttle comprises a frame, a clamp assembly configured to receive and grip blocks, and a wheel assembly connected to the frame for engaging the shuttle with a track. The wheel assembly includes at least one drive wheel assembly connected to at least one drive motor, enabling the shuttle to travel along the track, thereby transporting blocks to a block-laying robot via a boom. This allows the shuttle to receive blocks from a base of a robotic block-laying machine and travel along a boom to the block-laying robot without having to transfer the blocks to a separate handling mechanism. This reduces machine complexity and potential points of failure and helps ensure precise alignment of the blocks when the shuttle reaches the block-laying robot.

[0295] Furthermore, as previously mentioned, the block-laying robot can be configured to lay blocks by positioning a shuttle device near the block-laying location, enabling the shuttle device to release the blocks for laying. This effectively means that the shuttle device not only transports the blocks within the block-laying machine but also acts as part of the end effector to lay the blocks, thereby ensuring precise positioning of the blocks from transport to laying, which helps improve the accuracy of block positioning.

[0296] The wheel assembly includes upper wheels configured to run on top of the track segments and lower wheels configured to run beneath the track segments. Typically, the wheel assembly includes front and rear upper wheel assemblies, as well as front and rear lower wheel assemblies. It should be noted that the terms "front" and "rear" are relative terms based on the forward direction of the loaded shuttle in the machine. Since the shuttle does not turn when returning, traveling in the opposite direction, the "rear" end of the shuttle will face forward during the return trip.

[0297] Typically, one or more of the upper wheel assemblies are driven wheel assemblies connected to at least one drive motor, while the lower wheel assemblies are non-driven idler assemblies. The drive motor may be connected to at least one of the drive wheel assemblies via a belt and pulley mechanism or a chain and sprocket mechanism. Thus, one or more of the drive wheel assemblies is responsible for generating wheel traction, and one or both of the rear upper wheel assembly and the front upper wheel assembly may be driven. In other words, the shuttle device can be equipped with two-wheel drive or four-wheel drive, depending on the desired configuration.

[0298] To help keep the wheels on the track, the wheels of the front and rear lower wheel assemblies have spring preload to generate a normal force on the track.

[0299] In an embodiment, the drive wheels may be made of polyurethane, polyester-polyurethane, or rubber on a metal rim, and the non-drive wheels are typically made of acetal, plastic, or rubber.

[0300] Some of the wheels may also have flanges to position the shuttle laterally between the rails.

[0301] In some embodiments, the shuttle device further comprises a plurality of horizontal guide rollers located on both sides of the shuttle device frame to assist in guiding the shuttle device along the track.

[0302] The clamp assembly typically includes first and second movable jaw assemblies that open and close to release and clamp the block, respectively, although other suitable clamping structures may be used.

[0303] In one example, the clamp assembly includes a dual rack and pinion drive comprising a first rack mounted to the first jaw assembly and a second rack mounted to the second jaw assembly, and a clamp motor located below the jaw assemblies that drives a pinion that meshes with the two racks, such that rotation of the clamp motor in one direction causes the jaw assemblies to separate and open, and rotation of the clamp motor in the opposite direction causes the jaw assemblies to close. The rack and pinion drive also provides a strong correlation between motor torque and clamping force.

[0304] Additionally, the entire clamp assembly can be moved laterally by a side shift motor, thereby offsetting the clamp assembly (and the blocks) relative to the frame of the shuttle, which enables the shuttle to lay blocks alongside an existing party wall.

[0305] The clamp offset is achieved in the following manner: a jaw assembly is provided that is slidably mounted on a track set on the top of a support member across the shuttle device, and the shuttle device also includes a movable slide, to which the clamp motor and the side shift motor are mounted, the movable slide slides along the track set below the support member, and the side shift motor is operable to drive a pinion engaged with a rack mounted to the support member, so that the movable slide moves laterally, thereby offsetting the clamp assembly.

[0306] In one example, the jaw assemblies include opposing primary grippers for gripping opposing sides of a block, and optionally, at least one of the jaw assemblies further includes a pair of spaced, retractable secondary grippers disposed about opposing sides of the primary grippers. The shuttle mechanism includes an RC servo that actuates the secondary grippers, wherein the RC servo is operable to rotate the secondary grippers from a retracted position to an extended position, in which the grippers are configured to grip at least one side of the block in addition to the primary grippers. The secondary grippers can be used to grip longer blocks to ensure they are securely and accurately gripped, and are retracted when handling shorter blocks to avoid disturbing already laid blocks.

[0307] In one example, each shuttle is independent and equipped with its own power source. Typically, each shuttle has a battery pack containing one or more batteries, such as a plurality of lithium-ion rechargeable batteries, although other battery chemistries, such as lithium iron phosphate, may also be used. The shuttle includes a charging mechanism, such as an electric pickup assembly including carbon brushes, for engaging a charging track in the shuttle's storage area to at least partially charge the battery with each cycle through the machine. Alternatively, wireless charging via a tuned induction coil may be used.

[0308] The shuttles may include front and rear collision avoidance sensors for determining the distance between nearby shuttles to assist in avoiding collisions.

[0309] In addition, each shuttle device includes one or more sensors for calibrating the position of the shuttle device along the track, which sensors detect trigger targets distributed on the track, where detection of the trigger target causes the shuttle device controller to capture the encoder position of the shuttle device drive motor.

[0310] The sensors may include inductive proximity sensors or optical sensors. For example, one or more inductive proximity sensors used to calibrate the position of the shuttle on the track may be located on the side or below the shuttle. Alternatively, optical sensors on each shuttle detect reflective targets mounted at various locations on the base and boom tracks.

[0311] Inductive proximity sensors are used to detect trigger plates at various locations along the track throughout the conveyor and return loops. For systems using optical sensors, reflective trigger targets can be mounted along the track. When a trigger is detected using an inductive or optical sensor, the shuttle controller captures the encoder position of the shuttle drive motor and reports this as a position reference value to the central controller. Typically, the shuttle reports its position to the shuttle fleet controller as the distance traveled relative to its last captured position reference. The shuttle typically references its home position by contacting a hard stop on the second (rear) shuttle elevator.

[0312] The shuttles also include trigger plates that are detected by proximity sensors distributed throughout the delivery and return loop tracks. These sensors are used to confirm the presence of the shuttles at specific locations so that the central controller knows the location of each shuttle in the system and can coordinate traffic.

[0313] It should be understood that each position reference value has a unique identifier, and when the shuttle queue controller requests a shuttle device to move from its current position to a final position, the queue controller provides the shuttle device controller with a list of position reference value identifiers, including the starting position reference value identifier, the requested final position reference value identifier, and any intermediate position reference value identifiers that the shuttle device will detect during its travel from the current position to the requested final position. When executing a move request, the shuttle device controller records the most recently detected position reference value identifier and a list of position reference value identifiers that are expected to be detected when completing the current move request.

[0314] In this system, shuttles communicate with a shuttle fleet controller via a wireless communication network (e.g., Wi-Fi). In this regard, each shuttle includes a wireless receiver for receiving commands from the shuttle fleet controller and a wireless transmitter for sending status information to the shuttle fleet controller. Typically, commands received from the shuttle fleet controller indicate movement requests sent to the fleet controller from a central controller responsible for coordinating module movement and sequencing the tasks required to complete construction.

[0315] The shuttle controller is configured to control the drive system on the shuttle to execute the movement request, manage the charging of the batteries on the shuttle and report charging status information to the shuttle fleet controller, and monitor signals from sensors on the shuttle, and one or more of: modify the movement of the shuttle based on the received signals, and / or provide status information to the central controller based at least in part on information obtained from the received signals.

[0316] Each shuttle has permanent memory that records active commands, last known status, alarm history, last known position, type of block currently held, distance traveled since the last calibration point, and service life data (such as total operating time, total distance traveled, number of blocks held, model number, serial number, last maintenance date, and maintenance history).

[0317] The vehicle also includes an outrigger system for stabilizing the vehicle during operation with the boom deployed. The outrigger system is suspended from a support frame mounted to the chassis and includes front folding legs positioned on opposite sides of the vehicle. The front folding legs are pivotally connected to the foot pads, and during use, the legs are deployed at an angle to the ground. Furthermore, the front folding legs can be tilted forward to provide greater stability in the forward arc of the boom. The outer ends of the front folding legs are lowered, allowing the paving head (at the end of the boom) to lay close to the foot pads.

[0318] During operation, the front lower folding legs are deployed only on the building side of the vehicle to minimize intrusion of the vehicle's footprint onto the road.

[0319] Typically, the outrigger system also includes front jacks, each with a vertical plunger, which are mounted adjacent to the folding legs on the opposite side of the vehicle and are primarily used on the road side of the vehicle because their footprint is limited and does not extend onto the road.

[0320] At the rear of the truck, the outrigger system also includes rear pull-out legs on opposite sides of the vehicle, each having a vertical plunger that can be deployed in any of the leg's extended or stowed positions.

[0321] This outrigger combination provides the machine with versatile adaptability, allowing it to have wide support spans on building sides and narrow support spans on curbs. Primary stability is provided by the front folding legs, but front jack legs and vertical rams provide stability in narrow footprints at the front.

[0322] The option of using pull-out legs, folding legs or vertical rams can provide the vehicle with adequate stability while minimizing its footprint and fitting into tight construction sites, also allowing the vehicle to be parked and work from the roadside without having to extend the legs further into the road.

[0323] As mentioned above, the machine may optionally have a saw module to enable the blocks to be cut on the machine. Alternatively, the blocks may be pre-cut and sorted according to the build data file and placed on the pallet.

[0324] An example saw module will now be described. In this example, the saw is equipped with a wet diamond blade (water-cooled to remove dust and lubricate the blade to maximize blade life) and is capable of cutting bricks into squares, bevels, gable bevels, and reduced heights. These cuts can be performed on blocks with a maximum size of 600 x 300 x 400 mm (length x width x height), the largest size the machine is designed to handle. In one example, the saw blade has a diameter of 1100 mm.

[0325] In one example, a saw module (located in a machine base) includes a base frame and a gantry saw, the gantry saw including a gantry track mounted to the base frame, and a gantry frame connected to a saw blade and a motor, the gantry frame being slidably mounted to the gantry track for translation along the same. The saw module also includes a loading area having a cutting deck disposed adjacent to a floor of the base frame, upon which blocks to be cut are placed and from which blocks are subsequently retrieved. A first block translator is disposed adjacent to the cutting deck and is operable to move blocks in a direction orthogonal to a cutting direction of the saw blade. A fence is mounted adjacent to the cutting deck, and in use, blocks at least partially rest against the fence for support during cutting. A second block translator is disposed adjacent to the cutting deck and is movable in the direction of the saw blade's cutting for pushing blocks toward the fence or clamping the blocks against the fence during cutting.

[0326] In addition, the saw module may include a block rotation assembly operable to change the orientation of a block placed on the cutting board by 90 degrees, the block rotation mechanism including a finger assembly comprising a plurality of spaced-apart L-shaped fingers rigidly connected to a rotating rod rotated by an actuator; opposite ends of the rotating rod are connected to bushings that can slide along a guide rod, thereby enabling the finger assembly to translate in the same direction as the first block translator, and in use, the finger assembly is translated to position the fingers under the block, and then the finger assembly is rotated to rotate the block to a different orientation.

[0327] The block rotation assembly is located near one side of the cutting board, which has slots that align with the finger assemblies, allowing the fingers to freely translate and rotate across the cutting board to manipulate the blocks.

[0328] In one example, the first block translator includes first and second spaced-apart arms that are independently slidable along a mounting frame. The first and second arms extend beyond the cutting board, and each arm has a paddle attached to a distal end for pushing the block along the cutting board. Typically, each paddle is rotatable, allowing the angle of the paddle relative to the cutting board to be changed, thereby tilting the block for gable and miter cuts.

[0329] The blocks are loaded into and retrieved from the loading area of ​​the saw module by a transfer robot.

[0330] The saw may also have a waste chute to discharge waste chips.

[0331] The robotic block laying machine includes an onboard diesel truck engine-driven generator that can operate in generator mode or motor mode. The machine's electrical system is powered by either the generator or shore power.

[0332] The machine also includes a hydraulic system for the outriggers and for raising and lowering the boom. Its hydraulic pumps can be driven by the truck's diesel engine or, in electric motor mode, by a generator. In diesel engine mode, the diesel engine drives a power take-off (PTO) mounted on the transmission. The PTO is connected to a long drive shaft, which in turn drives a pump and electric generator to generate electricity.

[0333] In electric motor drive mode, shore power (such as on-site power at a construction site) turns the electric generator, which drives the hydraulic pump via a belt. In this mode, the PTO is isolated from the rotating drive shaft by a clutch because the PTO bearings and internal clutch plates are designed to not operate when the motor is stationary and the drive shaft is rotating. They require pressurized oil supplied by the gearbox for lubrication, and the gearbox must be rotated by the engine to provide oil pressure.

[0334] From the above description, it should be understood that the machine is designed with a modular architecture, each module can operate independently as an independent module. The machine has a highly distributed control architecture, and each module has its own industrial personal computer (IPC) and drive.

[0335] The robotic block laying machine typically also includes a control system, which typically includes one or more processing devices configured to control the shuttle device to move it from the base through the boom to the block laying robot, thereby transporting the blocks to the block laying robot; control the boom to move the block laying robot to the required position for laying the blocks; control the block laying robot to position the end effector near the distal end of the boom to receive the shuttle device, position the shuttle device near the block laying position so that the shuttle device releases the block and lays the block, position the end effector near the distal end of the boom to allow the shuttle device to return to the boom; and control the shuttle device to return its empty shuttle device along the boom to the base.

[0336] The control system also controls the transfer robot to pick up individual blocks (e.g., from a bag of blocks) and transfer each block to a corresponding one of a plurality of shuttle devices. The control system then independently controls each shuttle device to move along the boom to a block-laying robot disposed at the distal end of the boom, thereby transporting the blocks from the base to the block-laying robot.

[0337] For each block, the control system controls the boom to position the distal end of the boom relative to the block laying location and controls the block laying robot to lay the block.

[0338] The laying of blocks is typically achieved by the control system causing the block-laying robot to position the end effector near the distal end of the boom to receive the shuttle, positioning the shuttle near the block-laying position so that the shuttle releases the blocks and lays the blocks, and then positioning the end effector near the distal end of the boom so that the control system controls the shuttle to return the empty shuttle along the boom to the base.

[0339] The control system typically includes sensors that detect the position of the shuttle along the boom, and one or more processing devices configured to control the shuttle based on signals from the sensors.

[0340] The one or more processing devices typically adopt a distributed architecture, including: a central controller configured to manage the work plan that the robotic block laying machine needs to perform in a given construction; and a shuttle device queue controller, which communicates with the central controller (including receiving instructions indicating shuttle device work requests and providing shuttle device status information to the central controller) and wirelessly communicates with each shuttle device in the queue (including sending instructions to the shuttle device to perform the work requested by the central controller and receiving status information from the shuttle device).

[0341] The one or more processing devices further include at least one shuttle controller disposed in each shuttle, configured to control the shuttle according to instructions from the shuttle fleet controller.

[0342] At least one shuttle controller is configured to: control a drive system on the shuttle to execute a move request; manage battery charging on the shuttle and report charging status information to the shuttle queue controller; control the opening and closing of the clamps based on instructions received from the queue controller; and provide status information to the queue controller.

[0343] Typically, each shuttle also includes one or more sensors for referencing the shuttle's position along the track. These sensors detect trigger targets distributed along the track. Detection of the targets causes the shuttle controller to capture the encoder position of the shuttle's drive motor. The one or more sensors are one of the following: an inductive proximity sensor on each shuttle that detects a metal trigger target mounted along the track; or an optical sensor on each shuttle that detects a reflective trigger target mounted along the track.

[0344] The shuttle typically reports its position to the queue controller as the distance traveled relative to the last position reference it captured. Each position reference has a unique identifier. When the central controller issues a job request for the shuttle to move from its current position to its final position, it provides the queue controller with a list of position reference identifiers, including the starting position reference identifier, the requested final position reference identifier, and any intermediate position reference identifiers that the shuttle will detect between its current position and the requested final position. During the move, the shuttle controller records the most recently detected position reference identifier and a list of position reference identifiers that it expects to detect upon completing the current move request.

[0345] When laying blocks, the control system typically directs the block-laying robot to position its end effector and the shuttle mechanism attached to it at the block-laying location, then controls the shuttle mechanism to release the blocks. Specifically, the control system directs the block-laying robot to position its end effector near the distal end of its boom to receive the loaded shuttle mechanism, positions the shuttle mechanism near the block-laying location to allow the shuttle mechanism to release and lay the blocks, and then positions the end effector near the distal end of its boom to return the empty shuttle mechanism to the boom. The control system also directs the block-laying robot to move its elevator, transferring the empty shuttle mechanism from the end effector's lower track to the upper track after block laying, returning the empty shuttle mechanism to the boom.

[0346] When the lift includes a pneumatic actuation system, the control system may be configured to detect placement of the block by detecting exhaustion of a piston rod port of the pneumatic actuation system.

[0347] Typically, status information including the position of the shuttle is sent from each shuttle to a queue controller, which provides this information to the central controller, enabling it to coordinate the movement of track segments and other modules of the machine.

[0348] In a preferred embodiment, each shuttle device includes: a wireless transmitter for sending a status signal to the queue controller via a wireless communication network such as Wi-Fi; and a wireless receiver for receiving instructions from the queue controller via a wireless communication network such as Wi-Fi.

[0349] The one or more processing devices further include: a boom controller configured to control the boom according to instructions from the central controller; and a block-laying robot controller configured to control the block-laying robot according to instructions from the central controller.

[0350] Furthermore, one or more processing devices are configured to control at least one transfer robot to: pick individual blocks from a bag of blocks; and transfer each block to a corresponding one of a plurality of shuttles located at a loading location in the machine base. Preferably, a pair of transfer robots are provided to concurrently pick blocks from the bag of blocks and transfer them to the shuttles. One or more processing devices include a transfer robot controller configured to control the transfer robot based on instructions from the central controller.

[0351] The one or more processing devices are configured to control a plurality of bag conveyors to move the building block bags forward in the machine base to the empty bag stations. In this regard, the one or more processing devices include a bag conveyor controller configured to control the bag conveyors according to instructions from the central controller.

[0352] One or more processing devices are configured to control a shuttle sequencing system disposed in a machine base, the system comprising: a shuttle storage area comprising multiple levels of tracks on which shuttles travel and are stored when not in use; one or more shuttle elevators controlled to move shuttles to different levels of the tracks in the storage area; and a shuttle translator controlled to move shuttles into and out of the storage area. In some embodiments, the one or more processing devices include: at least one shuttle elevator controller configured to move shuttles between levels of the storage area in response to instructions from a central controller; and a shuttle translator controller configured to move shuttles into and out of the storage area.

[0353] The control system is further configured to control the turntable rotator to: receive loaded shuttles from the shuttle translator and travel the loaded shuttles to the tower track segments; receive empty shuttles from the tower track segments and travel the empty shuttles to the shuttle translator.

[0354] In some embodiments, one or more processing devices include: a turntable rotation controller configured to control the rotation of the turntable around the tower; and one or more turntable rotator controllers configured to control the rotation of the turntable rotator to respectively achieve shuttle device transfer between the turntable and the tower and the shuttle device translator.

[0355] Overall process flow of the machine

[0356] The machine utilizes a largely serial process. Blocks are loaded into the machine, processed sequentially and transported through the machine before being placed into the wall structure by a block-laying robot. Some parallel processes exist, such as two transfer robots operating simultaneously to process multiple blocks. A saw module cuts blocks while the transfer robots process other blocks. Three storage areas on the turntable (i.e., the turntable rotator) allow for pre-stocking of cut blocks as needed.

[0357] The process flow is briefly described below: The machine drives to the worksite. If the truck leaves the road, the anti-sinking mats stored under the machine can be manually deployed on soft ground. The outriggers are then deployed to stabilize the machine, and the boom is extended. Tracking equipment (such as a laser tracker and target) is removed from its storage area on the machine (not shown) and manually installed. In one example, a Leica Laser Tracker AT960 is used to track a T-Mac target mounted to the laying head to track the head's six-degree-of-freedom position and orientation.

[0358] The bales or pallets of blocks are then loaded onto the bale conveyor by a telehandler. The blocks are then photographed by a transfer robot and picked up using either a gripper gripper or a vacuum gripper, depending on the type of block being processed.

[0359] The transfer robot moves the blocks to the saw module for cutting or loads the blocks into the waiting shuttle. The transfer robot picks up the cut blocks from the saw. The saw discharges the waste.

[0360] The shuttle, loaded with blocks, travels along tracks on the shuttle storage area before reaching the translator. The shuttle briefly releases the block while a reference plate moves to precisely position the block on the shuttle, and the shuttle then re-grips the block. The translator then moves laterally to align with the turntable, and the shuttle travels to one of the three turntable rotators on the turntable. The turntable rotates to align the turntable rotator with the tower, and the turntable rotator rotates to align with the tower tracks.

[0361] The shuttle then travels up the tower to the tower rotator. The tower rotator rotates to align with the first boom element, and the shuttle then tracks through the first and second boom elements. Simultaneously, the tower rotator rotates back into alignment with the tower. The shuttle then travels to the luffing rotator. The luffing rotator rotates to align with the first rod element, and the shuttle then tracks through the first and second rod elements. Simultaneously, the luffing rotator rotates back into alignment with the boom element.

[0362] The shuttle then travels onto a shuttle rotator, which rotates the shuttle and blocks, and then an adhesive application system applies adhesive to the bottom of the blocks as the shuttle travels onto the end effector of a block-laying robot.

[0363] The laying arm then moves to position the end effector in the desired location to place the block on the wall. The final movement, optionally horizontal, closes the vertical gap between the ends of adjacent blocks. The shuttle then releases the block, and as the laying arm moves upward, the shuttle also moves upward via the elevator to the upper track of the end effector.

[0364] When the lay arm is fully retracted, the empty shuttle travels onto the waiting shuttle rotator while another loaded shuttle travels onto the lower track of the end effector below the empty shuttle.

[0365] The shuttle rotator then rotates to align with the mast, and the empty shuttle travels to the lower track of the second mast element. The shuttle then returns along the track on the second mast element, the first mast element, the luffing rotator, the second boom element, the first boom element, the tower rotator, the tower track, the turntable rotator, and the translator.

[0366] The translator moves laterally to transport the empty shuttle to the front shuttle elevator. The front shuttle elevator can be moved up and down to align with the middle or bottom track of the shuttle storage area. The empty shuttle is then driven into the shuttle storage area.

[0367] The control system sorts and selects the shuttles. The next empty shuttle to be used travels to the rear shuttle elevator, which moves upward to align with the upper rails of the shuttle storage area. The empty shuttle then travels forward to where it will be loaded by the transfer robot, and another cycle begins.

[0368] Further details of the process will be described below by referring to the various modules.

[0369] truck

[0370] Figure 2 An example of a vehicle 1 forming a platform on which a robotic block laying machine 20 is mounted is shown.

[0371] Vehicle 1 is in the form of a rigid-body truck that enables the robotic block laying machine 20 to be driven on roads to and from a construction site. In this example, truck 1 is an 8×4 rigid-body truck manufactured by Isuzu (e.g., model FYJ-350XLWB). Truck 1 has a typical driver's cab. In an alternative arrangement, a semitrailer connected to a tractor via a fifth wheel can be used instead of a rigid-body truck. Another alternative is to mount the block laying machine 20 on a trailer.

[0372] Truck 1 is used to install the robotic block laying machine 20 and transport the system to the construction site. Truck 1 carries all the necessary equipment, adhesives, and operators, but does not carry the required blocks, which are typically transported separately to the construction site. Truck 1 can optionally tow a trailer to transport a telehandler to the construction site.

[0373] The robotic block laying machine 20 is mounted above the chassis rails of the chassis 2. Some equipment, including a generator, hydraulic pump, tools, spare parts, cooling system, and anti-sink pads, is mounted to the robotic block laying machine 20, but is generally located below the top of the chassis rails. Some equipment, such as the rear undercarriage protection device (RUPD), is mounted to the chassis rails.

[0374] While an Isuzu truck is shown in this example, it should be understood that other suitable trucks could be used, such as Mack, Volvo, Mercedes, DAF, Scania, Freightliner, or Navistar. A suitable model comparable to the Isuzu FYJ-350XLWB in size, layout, chassis rail height, unladen weight, and engine power could be selected. Truck and / or machine modifications may be required to accommodate different truck chassis. It is also contemplated that electric trucks could be used, removing the generator and using an electric motor to drive the hydraulic pump. The truck's battery could be used to power the electrical equipment.

[0375] Support frame

[0376] Now refer to Figures 3A to 3C , shows an example of a support frame 10 mounted to the chassis 2 of a truck 1 to support a robotic block laying machine 20.

[0377] The support frame 10 is generally a frame capable of structurally supporting the machine 20. In the example shown, the support frame 10 includes a base frame 11 positioned above the chassis longitudinal beams and two upright side frames 12, 13. The base frame 11 provides mountings for the boom slew ring and mounting fixtures for the front and rear outriggers. For example, front outrigger mounts 14, 15, including cylinder mounts 14.1, 15.1, and rear outrigger mounts 16, 17 are shown. The side frames 12, 13 include mounting fixtures such as rails and racks (not shown) for supporting various modules in the machine base, including the transfer robot and pallet ejector.

[0378] The support frame 10 may also include a skin panel 18 that substantially covers the machine 20, helping to protect the machine's internal components from rain, wind, dust, sunlight, and other environmental factors, and providing security against internal hazards. The support frame 10 is a large welded component, consisting of three main components (a base frame and opposing side frames) that are machined and welded together into a single unit. In completely knocked-down (CKD) form for global shipping, it can be manufactured in smaller, bolted-together components to fit within a container. However, in a fully transported vehicle, it is more efficient to construct it as a single, welded structure.

[0379] The skin panel 18 may also include an access door 19 that can be opened from the exterior of the vehicle to access equipment such as a shuttle storage area.

[0380] Outrigger system

[0381] The vehicle 1 includes an outrigger system to stabilize the truck during operation and boom deployment. Figures 4A to 4C As shown, the vehicle 1 includes three different types of legs, allowing the vehicle 1 to have a wide stance on the building side of the machine and a narrow stance on the road side of the machine during operation.

[0382] The front outriggers 70, 71 are the primary stabilizing devices and are in the form of fold-down legs located at the front of the vehicle, behind the cab. The legs are pivotally connected to the front outrigger mounts, which have a forward attitude so that when deployed, the legs tilt slightly forward (and towards the ground), providing sufficient stability for the forward arc of travel of the boom.

[0383] exist Figure 4C , the front outrigger 71 is shown in the deployed state. The outrigger 71 includes a leg 71.1 pivotally connected to the front outrigger mounting 14. A foot (i.e., a foot pad or pad) 71.2 is pivotally connected to the leg 71.1 so that the outer end of the leg 71.1 is lower when folded down so that the paving head at the end of the boom can be close to the foot for construction. The front outrigger 71 includes a hydraulic cylinder 71.3, which is connected between the cylinder mounting 14.1 on the front outrigger mounting 14 and the leg 71.1. During operation, only one of the front outriggers 70, 71 is typically deployed to minimize the vehicle's footprint and intrusion into the road. During use, the front outriggers 70, 71 on the building side of the vehicle are deployed.

[0384] In addition, the outrigger system also includes front jack legs 72, 73 (i.e., vertical rams), which are also mounted to the front outrigger mounts 14, 15. These vertical rams can be deployed on the road side of the vehicle, and optionally on the building side, along with the front outriggers 70, 71, to provide additional stability. The front vertical rams provide narrow footprint stability for the vehicle.

[0385] At the rear of the vehicle 1, rear legs 74, 75 are provided in the form of extension legs with vertical plungers that can be deployed in any extended position of the legs. Figure 4B , the rear legs 74 are shown in an extended state. The rear legs 74 include a hydraulic ram 74.1 connected to a foot 74.2 and mounted to a slider 74.3, which is slidably connected to the rear leg mounting seat 17, thereby allowing the legs 74 to be pulled out to a desired position.

[0386] The option of using pull-out legs, folding legs or vertical rams provides the vehicle with sufficient stability while minimizing its footprint and fitting into tight construction sites. It also allows the vehicle to be parked and work from the roadside without having to extend the legs further into the road.

[0387] Package Conveyor

[0388] Now refer to Figures 5A to 5D An example of a bag conveyor 80 for conveying bags of blocks 6 through the machine is described.

[0389] In this example, bag conveyor 80 is a chain-type conveyor comprising a base frame 85 and a drive assembly comprising a plurality of chains 84 extending along the length of the base frame between a pair of shafts 82 and 83. Chains 84 are spaced apart across the width of base frame 85 and driven by a motor 81 connected to one of the shafts. In the example shown, motor 81 is connected to shaft 82 via a gearbox 81.1 and a shaft coupling 81.3. A plurality of sprockets are mounted on shafts 82 and 83, which mesh with chains 84.

[0390] The bag conveyors 80 are arranged as modules that can be mounted adjacent to each other and arranged in a single row in the base of the machine to provide a plurality of bag stations. Figure 5D The bales are shown arranged in a single file. In use, bales of blocks are fed into the rear of the machine onto a bale conveyor module, which is used to move the bales forward to an empty bale station. Typically, each bale conveyor 80 also includes guide plates 86, 87 mounted to opposite sides of the conveyor to assist in loading the bales and guiding the bales as the conveyor moves.

[0391] In such Figure 5BIn the illustrated configuration, three bag conveyors 80.1, 80.2, and 80.3 are used in the machine, each capable of accommodating up to three bales of building blocks. A bridge plate 88 is used to connect adjacent bag conveyors and is installed between adjacent frames 85.1 and 85.2 of bag conveyors 80.1 and 80.2. In this example, adjacent bag conveyors are slightly offset laterally from one another, causing the corresponding chains of each conveyor to be laterally staggered. This arrangement allows the ends of the chains of adjacent conveyors to be as close together as possible, allowing bales to easily transition from one conveyor to the next, which is crucial if the bales of building blocks are not placed on pallets.

[0392] Each bag chain conveyor 80 also includes a bag detection sensor, such as diffuse reflectance sensor 89, that emits a light beam across the conveyor. When a bag of blocks is on the conveyor at a particular bag station, the light beam reflects off the bag. In this way, the system can determine whether there are remaining blocks on the bag, or whether the bag is empty and its tray needs to be removed so that the following bag can move forward on the conveyor.

[0393] In another configuration, when the saw module is not installed, five inline pack conveyors may be provided, accommodating up to five packs of blocks to be loaded into the machine.

[0394] Tray ejector

[0395] Now refer to Figures 6A to 6G An example of the tray ejecting robot 90 for handling an empty tray is described.

[0396] The pallet ejection robot 90 is a Cartesian robot that provides linear motion in the X, Y, and Z directions. It picks up empty pallets from the bag conveyor and moves them to the pallet storage location. Although not shown in the figure, in one example, a rack is provided at the rear of the vehicle, and the empty pallets are stacked on the rack before being removed by a telehandler or similar device.

[0397] The tray ejection robot 90 is mounted to the side frame 12 of the vehicle 1, to longitudinally mounted side rails 12.1, 12.2 on the side frame 12. The tray ejection robot 90 comprises a carriage support 91 slidably mounted to the side frame 12 for longitudinal travel along the rails 12.1, 12.2.

[0398] The carriage 92 is slidably mounted to the carriage support 91 for vertical travel up and down the carriage support 91. The carriage 92 includes a body for traveling along the carriage support 91, and an engagement device 93 slidably mounted to the carriage 92 for transverse travel toward and away from the carriage support 91. In operation, an empty pallet 7 is secured by the engagement device 93 and picked up and moved to a pallet storage location.

[0399] In the illustrated example, the engagement means is in the form of a wedge-shaped clamp 93 having an opening or jaw 112 and including lower and upper jaws 110, 111, respectively, configured to engage the pallet. The jaws may include a tapered portion that assists in securing the pallet by increasing the frictional engagement between the jaws and the pallet when the wedge-shaped clamp is actuated to a fully engaged position.

[0400] like Figure 6D As shown, the wedge clamp includes an ultrasonic proximity sensor 113 for detecting the distance the pallet enters the clamping jaws during the travel of the carriage 92 toward the pallet.

[0401] In an alternative example, the engagement means may comprise a vacuum gripper that engages the pallet by suction, rather than a clamp structure. For example, one or more pneumatic suction elements may engage the top of the pallet to lift the pallet.

[0402] Mounted to the rear of the carriage support 91 are linear bearing blocks 95 and 96, which slidably engage rails 12.1 and 12.2 of the side frame 12. A motor 97 mounted to the carriage support 91 drives a pinion that meshes with a rack extending along one of the rails 12.1 and 12.2, facilitating movement of the robot in the vehicle's longitudinal X-direction. The carriage 92 has linear bearing blocks 102 and 103 that slidably engage rails 99 and 101 mounted to the carriage support 91. A motor 98 mounted to the carriage 92 drives a pinion that meshes with a rack 94 mounted to the carriage support 91, enabling vertical up and down travel along the carriage support 91 in the Z-direction. The wedge clamp 93 is mounted with linear bearing blocks 106 and 108, which slidably engage rails 107 and 109 mounted to the carriage 92. A motor 104 mounted to the wedge clamp 93 drives a pinion that meshes with a rack 105 mounted to the carriage 92 , enabling the wedge clamp 93 to travel laterally in the Y direction toward and away from the carriage support 91 to clamp the pallet 7 .

[0403] exist Figure 6F In the figure, wedge-shaped clamps 93 are shown fully extended relative to carriage 92 to the pick-up position, with the jaws engaging the empty pallet. Subsequently, carriage 92 and wedge-shaped clamps 93 are raised vertically on carriage supports 91, lifting pallet 7 from the pallet conveyor. Pallet ejection robot 90 then carries pallet 7 along side frames 12 toward the rear of the vehicle, placing it on a rack or pallet rest positioned between the opposing side frames of the vehicle. During transport, pallet 7 can be lifted over adjacent block pallets to a storage location.

[0404] Transfer robot

[0405] Now refer to Figures 7A to 7H An example of the transfer robot 60 is described.

[0406] As previously mentioned, the function of the transfer robot 60 is to pick individual blocks directly from the block tray and transfer them to another module in the machine base. The transfer robot 60 is configured to load blocks into an empty shuttle and, if the machine is equipped with a saw module, to move blocks into and out of the saw. In the example shown, two transfer robots 60 are used side by side to simultaneously load the shuttle and perform tasks, increasing efficiency.

[0407] In the illustrated example, the transfer robot 60 includes a column support 61 slidably mounted to the side frame 13 of the vehicle so as to slide along the side frame 13. Figure 7G As shown, the transfer robot is mounted on spaced longitudinal rails 13.1, 13.2 by linear bearing blocks 61.1, 61.2 mounted to column support 61. Also mounted to column support 61 is a motor 61.3 which drives a pinion which meshes with a rack mounted to side frame 13.

[0408] One end of beam 63 is slidably mounted to column support 61, allowing vertical movement up and down along column support 61. Column support 61 is equipped with tracks 61.4 and 61.5, along which beam 63 travels. A motor 63.1 mounted to the end of beam 63 drives a pinion that meshes with a rack 61.6 mounted to column support 61, facilitating movement. A pressurized gas strut 67 is also mounted to column support 61, with a chain 67.1 connecting the strut and beam 63. The gas strut 67 acts as a spring counterweight to support the weight of beam 63 and the blocks, reducing the required motor power and size. It also reduces the vertical force differential required for up and down movement, simplifying motor tuning and improving dynamic motion response. The gas strut 67 also helps provide controlled motion. In the event of a failure in the brake gearbox or pinion associated with the motor, the strut will return the gantry to a neutral buoyancy position, preventing it from impacting the floor and damaging equipment mounted to the beam.

[0409] A carriage 64 is slidably mounted to the beam 63 for travel therealong, and an arm 65 is slidably mounted to the carriage 64 for vertical movement up and down, wherein the distal end of the arm 65 includes a gripping mechanism 66 for picking up blocks from a bag of blocks.

[0410] A motor 131 mounted to the carriage 64 drives a pinion which meshes with a rack mounted to the beam 63. The beam also includes a track connected to a linear bearing block mounted on the carriage to allow sliding travel therealong.

[0411] Typically, the gripping mechanism 66 includes a pair of gripping fingers 138, 139 configured to grip the inner core of a block. The gripping fingers 138, 139 are driven open and closed by a rack and pinion system. Each finger 138, 139 is associated with a slidable jaw mounted to the base of the gripping mechanism 66. A motor 137 drives a pinion gear meshed between the rack gears mounted to the respective jaws, such that rotation of the pinion gear in one direction opens the jaws and rotation of the pinion gear in the opposite direction closes the jaws.

[0412] The base of the arm 65 includes a motor 133. The motor 133 is connected to a base 134 of the gripping mechanism 66 and is operable to rotate the gripping mechanism about a substantially vertical axis.

[0413] The gripping mechanism is rotatable about a rotation axis aligned with the longitudinal axis of the arm, enabling the arm to rotate a block held by the gripping fingers. In other arrangements, the gripper may be a vacuum gripper configured to pick up blocks (e.g., coreless blocks) by applying suction to the surface of the block. This is specifically designed for handling autoclaved aerated concrete (AAC) blocks.

[0414] Arm 65 Figure 7E and 7F The arm comprises an upper arm member 121 and a telescopic lower arm member 120. The upper arm member 121 includes a pair of tracks 129, 130 mounted thereto, which allow the lower arm member 120 to slide along a linear bearing block. The lower arm member 120 is connected to the upper arm member via a pulley-driven belt 124. The belt 124 loops around upper and lower pulleys 125, 126 mounted to the upper arm member 121. The belt 124 is clamped to the lower arm member 120 by a belt clamp 132.

[0415] The upper arm member 121 is driven up and down relative to the carriage 64 via a rack and pinion drive. Movement of the upper arm member 121 causes the lower arm member 120 to synchronously extend and retract relative to it. A motor 127 is mounted to the carriage 64 and drives a pinion, via a right-angle gearbox, that meshes with a rack 128 mounted to the upper arm member 121. The upper arm member includes additional tracks 122 and 123 that allow the arm 65 to move up and down relative to the carriage 64. When the arm 65 moves upward, the lower arm member 120 retracts into the upper arm member 121; when the arm 65 moves downward, the lower arm member 120 extends from the upper arm member 121.

[0416] To locate blocks on a bag for pickup, the transfer robot typically includes a vision system mounted to a beam for imaging the blocks on the bag, and one or more light sources to provide uniform illumination of the blocks. Preferably, the one or more light sources include a flash lamp that can overwhelm sunlight and other ambient light. The flash lamp provides illumination that is at least, and preferably, two orders of magnitude, higher than sunlight to ensure sufficient contrast for the vision system to detect the edges of the blocks. In other words, the flash lamp unit is approximately 10 to 100 times brighter than sunlight. In one example, the flash lamp is an ultra-bright xenon flash lamp.

[0417] In one example, the illuminated surface area is approximately 450 x 700 mm, with an illumination of 2000 W / m² at a surface distance of 600 mm. Typically, the spectral band of the flash unit is in the range of 400-800 nm, which is consistent with the quantum efficiency of cameras used in vision systems, such as the JAIGOX-12401M-PGE machine vision camera.

[0418] Typically, each flash delivers 120 joules of light, with flash duration adjustable from 0.01 milliseconds to 1 millisecond, and flash intensity variation of less than 5%.

[0419] Each flash unit typically has a driver configured to trigger a flash when the corresponding camera captures an image.

[0420] In the example shown, the vision system includes three cameras 68 spaced along the length of the gantry 63 to provide adequate viewing of the pallet in all operating configurations. Typically, each camera has an associated flash unit. In one example, the cameras are industrial area scan cameras, such as the GOX-12401C-PGE compact 12.3 megapixel camera.

[0421] As previously mentioned, in the example shown, two transfer robots 60 are provided for picking up individual building blocks directly from a bag. Figure 7G As shown, it is located in the base 5 and works concurrently to continuously feed the blocks into the shuttle device for delivery to the block laying robot at the end of the boom. Figure 7H As shown, each transfer robot 60 places blocks 4 picked from a bag into an empty shuttle 50 or saw module 150 (if used) waiting in the base 5. The transfer robot 60 can place blocks 4 into the loading area of ​​the saw 150 and retrieve cut blocks from the saw into the empty shuttle.

[0422] Shuttle device

[0423] Now refer to Figures 8A to 8L An example of the shuttle device 50 is described in further detail.

[0424] Shuttle 50 is a conveyor mechanism used to transport objects such as blocks, tiles, paving stones, or other building components from base 5 of machine 20 to block-laying robot 40 at the end of boom 30. As previously mentioned, the machine includes multiple shuttles that circulate along outbound and return tracks between base 5 and block-laying robot 40. An empty shuttle is loaded into the base and travels along the tracks to the block-laying robot, where the components are placed. The empty shuttle returns to the base along the return track.

[0425] In one example, a shuttle 50 grips a block 4 and transports it through the machine 20 to a block-laying robot 40, which then releases the block for placement on the wall. The machine utilizes a "continuous shuttle," meaning each shuttle is loaded, travels through the system, lays a block, and then returns. In this way, the shuttle continuously loops through the machine.

[0426] Each shuttle 50 includes a base frame 160. In the example shown, the base frame 160 includes a pair of opposing side panels 161, 162, a rear panel 163 located at the rear of the shuttle and mounted between the side panels 161, 162, and a front panel 164 located toward the front of the shuttle and mounted between the side panels 161, 162 (see FIG. Figure 8E ). At the front of the shuttle, a battery housing 165 is located forward of the front panel 164 and mounted between the side panels 161, 162. The battery housing 165 houses a plurality of batteries that power the shuttle. In one example, the batteries are 3.7 volt 21700 rechargeable lithium-ion batteries. In this example, each shuttle 50 contains 36 batteries, although the exact number required will vary depending on the power requirements of the shuttle (depending on the expected laying speed, block quality, and expected battery life).

[0427] In other arrangements, the shuttle may not have an on-board power source, but instead rely on power provided by the rails or tracks it travels on. In other arrangements, the battery pack may be replaced with or supplemented by supercapacitors.

[0428] The shuttle 50 includes a rear drive assembly 170 comprising a drive motor 171 connected to a gearbox 172 mounted to a motor bracket 173 connected to the side plates 161. The drive motor 171 is operable to drive a pair of rear drive wheels 178 via a belt 176 and pulley 174 mechanism connected between the motor 171 and a drive axle 177, which connects the rear drive wheels 178. The rear drive wheels 178 are positioned on opposite sides of the shuttle 50, exterior to the side plates 161 and 162. The rear drive wheels 178 are configured to run atop the track segments and transmit torque to propel the shuttle 50. In other arrangements, both the rear upper wheels and the front upper wheels are driven and can be connected to the drive motor via a sprocket and chain mechanism. In this manner, the drive system can be configured as either two-wheel drive or four-wheel drive, depending on traction requirements.

[0429] The rear drive assembly 170 also includes a pair of rear idler wheels 180 connected by an idler axle 181. The rear idler wheels 180 are positioned below the drive wheels 178 and are configured to run on the lower surface of the track segment. The idler axles 181 are connected to the base frame 160 via one or more tension springs 184 mounted between the rear plate 163 and lever arms 182 engaged near opposite ends of the idler axles 181. The lever arms 182 are pivotally connected to lever brackets 183 fixed to the respective side plates 161, 162. During operation, as the spring tension changes, the lever arms 182 pivot about the lever brackets 183, thereby adjusting the force acting on the idler axles 181 and, in turn, increasing or decreasing the friction between the rear idler wheels 180 and the lower surface of the track. The rear idler wheels 180 are also positioned on opposite sides of the shuttle 50, outside the side plates 161, 162, and have flanges to keep the shuttle on the track and prevent it from slipping, particularly when traveling along vertical or steeply inclined sections of track.

[0430] In one configuration, the drive wheel 178 comprises a metal rim with a rubber tire. Alternatively, the drive wheel can be made of polyurethane or polyester-polyurethane. The idler wheel 180 is made of acetal with a metal flange secured by screws.

[0431] The shuttle 50 also includes a front wheel assembly 190, which includes a pair of front upper wheels 192 configured to run on the top of the track segment and a pair of front lower wheels 202 configured to run on the lower surface of the track. The front wheel assembly 190 is supported by the front plate 164. The front upper wheels 192 are connected to a wheel frame 193, which is rigidly connected by a connecting plate 194, which is pivotally pinned to the front plate 164. This allows the front wheel assembly 190 to roll about the longitudinal shuttle axis and maintains contact with the track if the track twists.

[0432] The front lower wheel 202 is mounted to the opposite end of the front axle 203, and a pair of lever arms 204 are keyed to the front axle 203 near the opposite end of the front axle 203. One end of the lever arm 204 is pivotally connected to the lower portion of the corresponding wheel frame 193, and one or more tension springs 207 are connected between the spring support (such as a screw or bolt) passing through the other end of the lever arm 204 and the upper portion of the wheel frame 193. During operation, as the spring tension changes, the lever arm 204 pivots around the lower portion of the wheel frame 193, thereby adjusting the clamping force acting on the front axle 20 and clamping the wheel to the track. It should be noted that in this example, the front upper wheel and the front lower wheel 192, 202 are idler wheels, and only the rear upper wheel is a driven wheel. In other embodiments, the front upper wheel can also be a driven wheel, and an additional drive motor can be provided.

[0433] Now refer to Figures 8I to 8L Describe the clamping mechanism of the shuttle.

[0434] Each shuttle 50 includes a clamp assembly 210 for securely clamping or holding an object such as a brick or block. The clamp assembly 210 includes opposing first and second shuttle jaw assemblies 220, 230, each of which includes one or more clamps that can contact the side of the block when clamping. The clamp assembly 210 can be controlled to open or close the shuttle jaw assemblies 220, 230, respectively, to clamp or release the block. Each shuttle jaw assembly 220, 230 is mounted to a linear bearing block 224, 234, which is configured to slide along spaced-apart tracks 223, 233. The tracks 223, 233 are mounted to a track support block or plate 212, which is mounted between the opposing side plates 161, 162 of the shuttle 50.

[0435] The shuttle jaw assembly 220 includes a jaw 222 mounted to a linear bearing block 224 and includes a rack 225 mounted laterally to the jaw 222, with its teeth facing toward the rear of the shuttle 50. The shuttle jaw assembly 230 includes a jaw 232 mounted to a linear bearing block 234 and includes a rack 235 mounted laterally to the jaw 232, with its teeth facing toward the front of the shuttle 50. A motor 240 driving a spur gear (i.e., a pinion) is mounted vertically below the shuttle jaw assemblies 220 and 230. The spur gear is mechanically connected to the two racks 225 and 235, such that rotation of the motor 240 in a first direction causes the shuttle jaw assemblies 220 and 230 to open, and rotation of the motor 240 in a second direction causes the shuttle jaw assemblies 220 and 230 to close. In this way, a single actuator can open or close the shuttle jaws using a dual rack and pinion drive.

[0436] The shuttle jaw assemblies 220, 230 each include opposing main grippers 226, 236 that include gripper pads 227, 237 secured or bonded to pad mounting brackets 228, 238 upstanding from the respective jaws 222, 232. In the example shown, these main grippers 226, 236 are wide to increase the surface area of ​​the pads that can come into contact with the blocks.

[0437] To accommodate longer blocks, the shuttle jaw assembly 230 also includes a pair of spaced, retractable secondary grippers 250 positioned on opposite sides of the primary gripper 236. The secondary grippers 250 include pads 252 secured or bonded to pad holders 254, which are rotatably connected to a remote control (RC) servo 256. The RC servo, comprising a motor and a gear train, is operable to rotate the secondary grippers 250 from a retracted position, in which the grippers are positioned horizontally, to an extended position, in which the grippers are positioned vertically above the jaws 232. In this manner, the secondary grippers 250 pivot upward and downward, allowing them to be gripped by both the primary and secondary grippers simultaneously when a long block is to be gripped, ensuring a secure and accurate hold. When not in use, the secondary grippers 250 retract to avoid interference with adjacent blocks in the wall under construction.

[0438] When the shuttle is loaded in the shuttle storage area, the blocks are placed on top of the shuttle and rest against the surfaces of the respective jaws 222, 232 and are then gripped by the primary and optional secondary grippers of each jaw assembly.

[0439] In some cases, it may be necessary to be able to offset the masonry block held in the shuttle assembly 50, such as when working near an existing party wall. The shuttle assembly 50 achieves this function using a motor 260 positioned horizontally below the jaw assemblies 220 and 230. Motor 260 is mounted to a motor bracket 261, which also positions the motor 240 that drives the jaw assemblies 220 and 230. Motor 260 drives a spur gear 262 that meshes with a rack 264 mounted below the track support block or plate 212. Motor bracket 261 is connected to a linear bearing block 265 that slides along rails 266 and 267 mounted on the lower surface of the track support block or plate 212. Thus, motor 260 is configured to drive the two shuttle jaw assemblies 220 and 230 to move synchronously laterally along the rails 266 and 267, thereby offsetting the clamped masonry block relative to the shuttle assembly 50. In the fully displaced position, the shuttle jaw assemblies 230 and the clamped masonry block extend out the side of the shuttle assembly.

[0440] The shuttle 50 also includes an electrical pickup assembly 270 mounted to the side panel 162 (e.g., Figure 8E), which includes one or more carbon brushes 272 arranged in a brush mounting housing 271 such that the brushes 272 are suspended below the shuttle 50 for picking up power from a charging track in the shuttle storage area. In the example shown, the brushes 272 are spring-loaded to ensure reliable contact with the charging track, allowing the shuttle 50 to at least partially charge the battery while in the shuttle storage area of ​​the machine.

[0441] In order to control the movement of multiple shuttles that move continuously in a machine, the position of each shuttle 50 in the system must be accurately known. The shuttle drive motor 240 includes an absolute position encoder that is used to estimate the distance traveled, and this data is input into the shuttle's position algorithm. However, wheel slip, mechanical wear, slight differences in the physical dimensions of different shuttle units, and the presence of telescopic sections of track mean that absolute shaft encoder readings cannot provide accurate position data in the long term. The encoder readings need to be recalibrated regularly to a known physical position. To provide a reliable and accurate positioning system, each shuttle is equipped with a proximity sensor (such as an inductive proximity switch) that can detect metal triggers (such as plates, bolt heads) at different locations along the track. In addition, proximity sensors are installed at different locations on the track and triggered by a trigger plate on the shuttle to clearly determine the presence of the shuttle at that location. In an alternative arrangement, an optical proximity sensor can be used in combination with a reflective trigger target.

[0442] exist Figure 8C and 8D In the example shown, two inductive proximity sensors 280, 282 are mounted on the shuttle 50. The first inductive proximity sensor 280 is mounted to the side of the shuttle 50, while the second inductive proximity sensor 282 is mounted to the bottom of the shuttle 50. This enables the shuttle 50 to detect triggers located along the track to the side of the shuttle or alternatively underneath the shuttle. Figure 8C As shown, the side plate 161 also includes an upwardly projecting striker plate 284 for detection by inductive proximity sensors distributed around the track throughout the machine to confirm the presence of the shuttle device on a specific section of the track.

[0443] The shuttle 50 may also include collision avoidance proximity sensors (e.g., ultrasonic sensors) located at the front and rear of the shuttle to prevent collisions between nearby shuttles. Alternatively, laser-based proximity sensors may be used to monitor the distance between shuttles moving along the track. The shuttle's processing equipment monitors the signals received from the collision avoidance sensors and controls the drive system to modify the speed or brake the motor based on the received signals to ensure collisions with other shuttles or objects are avoided.

[0444] The shuttle device 50 also includes at least one self-contained shuttle device controller. Typically, the shuttle device includes a primary controller, which in one example comprises a Raspberry Pi running an EtherCAT master. A secondary controller may also be provided, configured to control power to the primary controller and brake the drive motor if the primary controller is unavailable.

[0445] The shuttle controller is generally configured to: wirelessly receive instructions indicating movement requests from the shuttle queue controller; control the drive system on the shuttle to execute the movement request; and wirelessly return status information at least partially indicative of the status of the movement request to the shuttle queue controller.

[0446] Each shuttle device communicates with the shuttle device queue controller via a wireless communication network such as Wi-Fi. Typically, messages between each shuttle device and the shuttle device queue controller are transmitted via an MQTT agent over the Wi-Fi network.

[0447] Typically, status information including the position of the shuttles is sent from each shuttle to a shuttle fleet controller, which provides this information to the machine's central controller, which is responsible for coordinating the movement of the shuttles between the tracks.

[0448] Shuttle device sequencing system

[0449] Now refer to Figures 9A to 9L The shuttle sequencing or management system 300 is described in further detail.

[0450] The shuttle sequencing system 300 is located in the base 5 of the machine 20 and provides storage for the location of the shuttles, the ability to sequence the order of the shuttles, and a power source for charging the shuttle batteries. The shuttle sequencing system 300 is responsible for sequencing the shuttles to and from the carousel and additionally provides a location for the transfer robot 60 to load blocks onto the shuttles.

[0451] The shuttle sequencing system 300 includes a shuttle storage area 310 containing multiple levels of tracks on which shuttles travel and are stored when not in use. The shuttle sequencing system 300 also includes first and second shuttle elevators 330 and 340, respectively located at the front and rear of the storage area 310, configured to lift shuttles disposed thereon to different levels of tracks in the storage area 310, and a shuttle translator 350, located adjacent to the front elevator 330, operable to move shuttles into and out of the shuttle storage area 310. The shuttle translator 350 moves shuttles between the shuttle storage area 310 and the turntable.

[0452] exist Figure 9GIn the example shown, the shuttle storage area 310 includes three levels of rails, namely a top rail 312, a middle rail 314, and a bottom rail 316. Each rail 312, 314, 316 comprises a pair of spaced apart angle profile rails, the distance between the rails corresponding to the wheel spacing of the shuttle 50. A rubber strip may be bonded to the upper surface of each rail to improve traction with the shuttle wheels. Each level of rails also includes an associated charging rail 322, 324, 326 (see FIG. Figure 9I ) that can make contact with the electrical pickup 272 of each shuttle 50. Charging tracks 322, 324, 326 securely hold copper conductors along the length of the tracks, which carry power and charge the batteries of each shuttle in the storage area 310. Figure 9I and 9J As shown, the charging rails 322 , 324 , 326 are mounted below the corresponding rails 312 , 314 , 316 .

[0453] In operation, the top track 312 is used to load an empty shuttle, and the shuttle, after being loaded with blocks, travels forward along the top track 312 toward the shuttle translator 350. The empty shuttle on the top track 312 receives blocks from one of the transfer robots 60. The middle and bottom tracks 314, 316 are used by the returning empty shuttle, so the shuttle travels on these tracks toward the rear of the machine and the rear elevator 340.

[0454] Tracks 312, 314, 316 are mounted to a frame structure 304 which is mounted to the floor of the base 5 of the machine 20, proximate the side frames 13. The shuttle storage area 310 also includes a plurality of proximity switches 302 associated with each level of track and spaced apart along the length of the storage area 310 which detect the trigger 284 on each shuttle 50 to confirm the presence of a shuttle at that location in the storage area 310. The storage area 310 also includes a plate 305 mounted below each track 312, 314, 316 (opposite the charging track) on which are mounted spaced apart triggers 303 which are detected by the inductive proximity sensors 282 on each shuttle to calibrate the position. The triggers 303 are located at defined calibrated positions in the storage area. At Figure 9I In the example shown, the trigger 303 in the shuttle storage area 310 is a bolt head or a screw head.

[0455] In the illustrated example, the storage area 310 is an elongated structure comprising three sections: a rear section 311, a middle section 313, and a front section 315. The middle section 313 opens like a door, allowing the shuttle device to be removed or added, or for maintenance to be performed outside the machine. In this regard, an access panel is provided on the exterior of the machine, allowing a user to open the pivotable middle section 313 of the storage area 310. The middle section 313 opens about a pivot 313.2 in response to operating a handle 313.1 to unlock the middle section 313.

[0456] Now refer to Figure 9B and 9C The shuttle elevators 330 and 340 are described. The front shuttle elevator 330 travels between the bottom track 316 and the middle track 314 of the shuttle storage area 310, and the rear shuttle elevator 340 travels between the top track 312, the middle track 314, and the bottom track 316. The elevators 330 and 340 enable the shuttle 50 to be raised or lowered to different levels of track as needed.

[0457] Each shuttle lift 330, 340 includes a lift frame 331, 341 connected to the side frame 13 of the vehicle 1, and a lift tray 332, 342 slidably connected to the lift frame 331, 341 for vertical travel up and down the frame. The lift tray 332, 342 includes a body 333, 343 having lift track segments 334, 344 that can engage with the wheels of the shuttle. The lift tray 332, 342 accommodates a single shuttle and operates to align the lift track segments 334, 344 with the tracks of a certain level of the shuttle storage area 310.

[0458] Each elevator tray 332, 342 comprises a U-shaped base having an upright plate member 333.1, 343.1 slidably connected to the elevator frame 331, 341 by a linear bearing block 339.1, 349.1 which slides along a track 339, 349 mounted to the elevator frame 331, 341. A motor 336, 346 mounted to the elevator frame 331, 341 drives a pinion 337, 347 which meshes with a rack 338, 348 through a right angle gearbox to move the shuttle elevator tray 33, 342 up and down.

[0459] The rear shuttle elevator 340 includes a hard stop 343.2 to which the shuttle 50 travels, providing a reference for the starting position of the shuttle 50. Each shuttle elevator 330, 340 also includes an inductive proximity sensor 335, 345 mounted to the plate member 333.1, 343.1 for detecting the trigger 284 on the shuttle 50, and a trigger (not shown) mounted to the bottom of the elevator tray 332, 342, which is detected by the proximity sensor 280 of the shuttle 50. Alternatively, an optical proximity sensor and a reflective trigger may be used.

[0460] The shuttle translator 350 moves the shuttles 50 in a direction of travel that is orthogonal to the direction the shuttles move in the shuttle storage area 310. In use, the shuttle translator 350 individually translates the shuttles 50 between the shuttle storage area and the turntable.

[0461] like Figures 9D to 9F As shown, the shuttle translator 350 includes a translator base 351 mounted to the base frame 11 of the vehicle 1. The translator base 351 includes a track 352 extending along the direction of travel of the shuttle translator 350. A translator assembly 354 is slidably connected to the translator base 351 for sliding travel there along. The translator assembly 354 includes a body 354.1 that slides along the track 352 via a linear bearing block 355. The translator assembly 354 is driven by a motor 356, which drives a pinion that meshes with a rack 353 mounted to the translator base 351. The body 354.1 is a U-shaped structure with first and second translator track segments 357, 358 mounted on its side walls, each of which can engage with the wheels of the shuttle 50. In this manner, the shuttle translator 350 includes upper and lower track segments 357, 358, with the shuttle translator's track segments being orthogonal to the translator's direction of travel.

[0462] In the first position of the shuttle translator 350, the first translator track segment 357 (upper track segment) is aligned with the top track 312 of the shuttle storage area 310 for receiving the departing shuttle thereon. That is, the loaded shuttle travels along the top track 312 of the shuttle storage area 310 to the top track of the shuttle translator 350. The second translator track segment 358 (lower segment) accommodates the return shuttle. In use, the forward elevator 330 is raised so that its track segment 334 is aligned with the second translator track segment 358, allowing the return shuttle to travel from the shuttle translator 350 to the forward elevator 330 for return to the storage area 310.

[0463] The shuttle translator 350 also includes inductive proximity sensors 359 at each level of track 357, 358 for detecting the trigger plate 284 on the shuttle 50, and a trigger (not shown) detected by the proximity sensor 280 of the shuttle 50. Alternatively, an optical proximity sensor and a reflective trigger may be used.

[0464] The shuttle sequencing system 300 also includes a shuttle datum assembly 360 for determining the position of blocks in the fixture assembly 210 of each shuttle 50. Datum assembly 360 is located adjacent to the shuttle translator 350, near the distal ends of the translator track segments 357, 358. Datum assembly 360 is mounted to translator base 351 via a frame 361. Datum assembly 360 includes a slidable arm 362 with a datum plate 363 mounted at its distal end, which is positioned vertically above the top track 357 of the shuttle translator 350. A motor 364 is mounted to the frame 361 and drives a pinion 365 that meshes with a rack 366 mounted to the arm 362 of the datum assembly 360. The arm 362 is mounted to a linear bearing block that slides along a track 367.

[0465] Thus, the reference plate 363 is able to move along the length of the translator track segment 357, and its position can be varied depending on the type of blocks being loaded by a particular shuttle device.

[0466] In use, when a loaded shuttle is driven from the shuttle storage area 310 to the top rail 357 of the shuttle translator 350, the reference plate 363 will translate to a known reference position for the specific block type (the reference position will vary depending on the length of the block). The shuttle 50 will release the block it is carrying or loosen the clamps to allow the block to be moved by the reference plate 363. The shuttle 50 pushes the block toward the reference plate, causing it to stop in that position. The shuttle 50 continues to travel forward until it contacts the shuttle hard stop 368 mounted to the frame 361 of the reference assembly 360. The shuttle then re-grips the block at the reference position, and the block is ready to be translated by the shuttle translator 350 to the turntable 400.

[0467] Figure 9K and 9L The shuttle translator 350 is shown in a second position, having been translated laterally to the turntable 400 and aligned with the track of the turntable rotator 410 , enabling the shuttle 50 to transition between the shuttle translator 350 and the turntable 400 .

[0468] turntable

[0469] Now refer to Figure 10A and 10B The turntable 400 is described.

[0470] The turntable 400 is located in the base 5 of the machine 20 and is mounted concentrically with the boom slew ring at the bottom of the tower 31. The turntable 400 is rotatable about the tower 31 and includes a plurality of radially spaced turntable rotators 410, each of which is configured to receive a loaded shuttle 50 from the shuttle translator 350 and rotate it to align the loaded shuttle 50 with the tower track segment, or to receive an empty shuttle from the tower track segment and rotate it to align the empty shuttle with the shuttle translator 350.

[0471] The turntable 400 includes a turntable bracket 402, which is mounted concentrically with the boom slew ring to the base frame 11. A lubricated inner bearing ring 404 is mounted to the turntable bracket 402, and an outer slew ring 405 is rotatably connected to the inner bearing ring 404. A motor 406 is mounted to the turntable bracket 402 and drives a gear 407, which meshes with the teeth of the outer slew ring 405, through a right-angle gearbox, causing the slew ring 405 to rotate about the fixed inner bearing ring 404.

[0472] The turntable rotator 410 is mounted to the top of the outer slewing ring 405 and rotates with the outer slewing ring 405. Each turntable rotator 410 includes first and second turntable rotator track segments 412, 414 spaced apart and mounted to opposite sides of a U-shaped body 411. The U-shaped body 411 is pivotally mounted between a pair of spaced apart support arms 413, which are connected to a base plate 415 fixed to the outer slewing ring 405. A motor 416 is mounted to one of the support arms 413 via a reduction gearbox (or Spinea Twinspin bearing reducer) 417 directly mounted to the pivot joint of the arm 413. This transmission mechanism allows the U-shaped body 411 of the turntable rotator 410 to rotate from a first position to a second position. In the first position, the rotator tracks 412, 414 are aligned with the track segments 357, 358 of the shuttle translator 350, and in the second position, the rotator tracks 412, 414 are aligned with the tower track segments.

[0473] In the example shown, the turntable 400 has three turntable rotators 410 that can store shuttles with, for example, cut blocks required for a block laying sequence. It will be understood that a different number of turntable rotators may be provided depending on the machine configuration and the amount of buffering / storage required to execute the block laying sequence. The turntable 400 is powered by electrical slip rings 420 that allow for continuous rotation, enabling the turntable to move in the shortest direction to the next destination without being constrained by power cables. The slip rings 420 are mounted below the base plate 415 of the turntable rotators 410, outside the inner and outer rings 404 and 405. The slip rings 420 transmit power to the turntable 400 via collector brushes 422 connected to collector arms 423, which contact insulated copper rails 421 inside each ring during rotation. The slip rings and brushes are manufactured by Conductix Wampfler.

[0474] The turntable rotator 410 also includes an inductive proximity sensor 418 at each level of track 412 , 414 for detecting the trigger plate 284 on the shuttle device 50 ; and a trigger 419 at each level of track 412 , 414 , which is detected by the proximity sensor 282 of the shuttle device 50 .

[0475] In use, the shuttle translator 350 is moved laterally from the shuttle storage area 310 to the turntable 400, which is rotated to align one of the turntable rotators 410 with the shuttle translator 350, allowing the loaded shuttle to travel to the turntable rotator 410. The turntable 400 is then rotated to align the loaded turntable rotator track segments 412 with the tower track segments 442, allowing the shuttle to travel to the tower 31 (e.g., Figure 10C and 10D shown).

[0476] Note that the boom 20 needs to be swiveled intermittently and almost continuously to move the block-laying robot 40 around the construction site, so during the transition of the shuttle 50 between the turntable 400 and the tower 31, the rotation of the turntable 400 is slaved to track the swinging motion of the boom.

[0477] tower

[0478] Now refer to Figures 11A to 11E The tower 31 is described.

[0479] Tower 31 is mounted via base 440 to the boom slewing ring, which rotates to the desired building angle. The boom slews using a ball bearing slewing ring with an integrated ring gear. The slew drive is provided by two servo motors acting on a pinion gear through a bearing reducer (Spinea Twinspin). The use of two motors provides sufficient torque to resist the slewing torque generated by the wind blowing against the sides of the boom. The two motors also serve to eliminate backlash.

[0480] The tower 31 is supported by the boom slew ring and in turn supports the boom 30. The tower 31 includes a body 441 having a boom pivot about which the proximal end of the boom pivots. Figure 11A As shown, the tower 31 includes two mounting ears 445, 446 at the boom pivot, about which the bulkhead of the first boom element is pivotally mounted. Another ear 447 is provided on the tower 31, to which one end of the hydraulic lifting cylinder of the boom is connected.

[0481] The main body 441 of the tower 31 supports tower track segments that allow the shuttle to travel along the tower. A pair of fixed tower track segments 442, 443 are mounted to one side of the tower 31 for receiving loaded shuttles from the carousel rotator 410 or receiving empty return shuttles from the tower rotator 450, as will be described in further detail below.

[0482] The tower rotator 450 is pivotally mounted to the tower 31 to pivot coaxially with the boom pivot. In the illustrated example, the tower rotator 450 includes a body having tower rotator track segments 452, 453 configured to receive one of a loaded shuttle bound for the block laying robot 40 or an empty shuttle returned to the shuttle storage area 310. In this regard, the tower rotator 450 is configured to be in a first position (see FIG. Figure 11C ) and the second position (see Figure 11D and 11E ) in which, in a first position, the tower rotator rails 452, 453 are aligned with the tower track segments 442, 443 to transfer the shuttle device to and from the tower 31; in a second position, the tower rotator track segments 452, 453 are aligned with the boom track segments to transfer the shuttle device to and from the boom.

[0483] During the transition of the shuttle device between the tower rotator 450 and the boom 30, the pivoting movement of the tower rotator 450 is slaved to the lifting angle of the boom. In this regard, a hydraulic lifting cylinder for the boom is provided, which is mounted to the tower, as will be described in further detail below.

[0484] The tower rotator 450 is actuated by an electric servo motor 455, which drives a pinion through a planetary gearbox. The pinion drives a gear that pivots the tower rotator 450. The servo motor has an integral absolute encoder and a brake. A proximity switch 454 is used to confirm the alignment of the tower rotator with the tower 31 and the first boom element. The proximity sensor detects that the shuttle is in the correct position to allow rotation. Proximity sensors 444 and triggers are also provided near the tower track segments 442 and 443 to detect the shuttle and allow it to calibrate its position.

[0485] Boom system

[0486] Figures 12A to 12C The boom system 30 is depicted in a folded transport position.

[0487] The first boom element 32 is pivotally connected to the tower 31 via its bulkhead 505, which is bonded to the first boom element 32 at its proximal end. A hydraulic lift cylinder 530 provides the lifting force to raise and lower the first boom element 32 and is connected between the tower 31 and the bulkhead 505 of the first boom element 32. The second boom element 34 is telescopically connected to the interior of the first boom element 32 and includes a bulkhead 545 at its distal end. The first rod element 36 has a bulkhead 575 at its proximal end and is pivotally connected to the second boom element via a pivot or luffing joint. A pair of symmetrically arranged hydraulic cylinders 532 are connected between the second boom element 34 and the first rod element 36, providing the luffing force to manipulate the rod angle. The hydraulic cylinders 532 are connected between a fitting 578 on the first rod element 36 and a dogbone link 550, which is connected between the bulkhead 545 of the second boom element 34 and the bulkhead 575 of the first rod element 36. The second rod element 38 is telescopically connected to the interior of the first rod element 36 , and its distal end is pivotally connected to the block laying robot 40 .

[0488] The first movable arm element 32 (see Figures 13A to 13E) is mounted to the tower 31 by a welded steel bulkhead pivot fitting 505, which is bonded to a composite carbon fiber tube consisting of four flat sandwich panels 501, 502, 503, and 504, bonded at the corners to a stack of aluminum profiles or carbon fiber corner profiles. Ultra-high modulus pre-impregnated carbon fiber is used to achieve high stiffness at low weight. The bulkhead 505 is pivotally mounted to the tower 31 about mounting ears 508 and 509 on opposite sides of the bulkhead, which are pinned to corresponding ears 445 and 446 on the tower 31. The bulkhead 505 includes another ear 510 through which a hydraulic cylinder 530 is connected. One end of the cylinder 530 is connected to the ear 447 of the tower 31, so that extending and retracting the cylinder 530 causes the boom lift angle relative to the tower to change.

[0489] The first boom member 32 includes a pair of inner rails, comprising a top rail 512 and a bottom rail 514, mounted offset from its side panels via brackets 511, 513 connected to the bulkhead 505 of the first boom member 32. The rails of the first boom member 32 form inner rails that are telescopically connected to the corresponding outer rails of the second boom member. To this end, the rails include upper and lower bosses 515, 516 configured to slidably interconnect with corresponding channels forming part of the rails of the second boom member, as described in further detail below. In the illustrated example, the rails of the first boom member 32 comprise a composite core inserted into a C-shaped carbon fiber rail web portion.

[0490] like Figure 13E As shown, the first boom element 32 supports self-aligning linear roller bearing blocks 531, 532 (e.g., bearing slides) for the telescopic movement of the second boom element 34, which is telescoping within it. The bearing blocks 531, 532 are mounted to a fitting 530 mounted within the tube. The first boom element 32 typically includes linear roller bearing blocks at both the upper and lower portions of the boom element, along which the second boom element 34 slides. Wear pads 533 are also typically mounted within the first boom element, over which the telescoping element slides. The wear pads serve as sacrificial wear parts and laterally position the second boom element 34. The bearing blocks are slightly pitched and rolled to ensure that all contact rollers evenly contact the steel bearing strips of the second boom element.

[0491] The second boom element 34 is telescopically moved by a chain 520 driven by a sprocket 522 driven by a geared electric servo motor mounted on the first boom element 32. In the illustrated example, a pair of motors 506 and 507 are mounted on opposite sides of the bulkhead 505, each driving a sprocket 522 and chain 520 on an opposite side of the boom element. The chain 520 is connected to the second boom element 34 via an adjustable chain connection element mounted on an exterior fitting of the second boom element 34, which allows for adjustable chain tension. The chain drive forms an endless loop and acts as a winch to extend and retract the second boom element. A dual chain arrangement is provided for redundancy.

[0492] The second movable arm element 34 (such as Figures 14A to 14I The 6061-0 aluminum luffing joint 545 is heat treated to 6061-T6 or 6061-T4 after welding. The composite tube is constructed from four flat sandwich panels 541, 542, 543, 544, which are bonded to aluminum extrusions or built-up carbon fiber angle sections at the corners. Ultra-high modulus pre-impregnated carbon fiber is used to achieve high stiffness at low weight.

[0493] In one example, the aluminum corner profile has a dovetail groove in which the hard steel bearing strips are captured. The shape of the corner profile simplifies the bonding process. In the example shown, carbon fiber corner profile stacks are used at the corners to bond the panels together. Steel bearing strips 546, 547 are installed along the upper and lower corner surfaces and are as shown in the figure. Figure 14B Shown is mechanically clamped via angled retaining plates fixed to steel bearing strips.

[0494] As previously described, the second boom member 34 is telescopically moved by a chain 520 driven by a sprocket 522 driven by geared electric servomotors 506 and 507 mounted on the first boom member 32. The second boom member 34 includes a pair of adjustable chain connecting members 548 and 549 mounted on fittings on either side of the second boom member 34. Each chain 520 is disconnected at this location and each end is pinned to one of the chain connecting members 548 and 549 to connect the chain to the second boom member 34. The chain connecting members 548 and 549 can be adjusted to vary the tension in the chain 520. Therefore, it can be understood that the telescopic movement of the boom member is driven by redundant dual chains and electric servomotors.

[0495] Hardened steel bearing strips 546, 547 are mounted along the upper and lower corners of the second boom element 34 to provide bearing surfaces for telescopic movement within the first boom element 32. In the illustrated arrangement, the bearing strips 546, 547 are held in place by long plates fixed to the corners of the tube. In an alternative arrangement, aluminum extrusions are used to bond the carbon fiber sheets, and the extrusions are fabricated with dovetail grooves in which the bearing strips are captured.

[0496] The second boom member 34 has internally mounted tracks including a top track 552 (along which the loaded shuttle 50 travels to the block laying robot) and a bottom track 554 (along which the empty shuttle 50' returns), as shown in FIG. Figure 14F and 14GAs shown. The track forms part of a C-shaped carbon fiber channel profile that is mounted to the opposing inner surfaces of the side panels 542, 544. The profile captures U-shaped channel inserts 553, 555 made of acetal at the upper and lower corners near its web portion. The web of the C-shaped carbon fiber track profile includes a composite core to provide strength and reduce the weight of the track. In use, the track of the first boom member 32 is telescoped inside the track of the second boom member 34, mounted to the track bosses 515, 516 (see Figure 13C ) are received in slot inserts 553, 555 forming part of the track of the second movable arm member 34 to facilitate telescopic movement of the corresponding track.

[0497] At the distal end of the second boom member 34, near the luffing rotator 560, is a short static track segment comprising a top track element 556 and a bottom track element 557. This track segment provides a waiting position for the shuttle until the luffing rotator 560 is aligned with the second boom member 34, and also allows the boom and pole to use a common telescoping track (since the boom member is slightly longer than the pole member).

[0498] The luffing rotator 560 is mounted to the luffing joint pivot fitting (e.g., bulkhead) 545 so that its rotation axis is aligned with the pivot axis between the second boom member 34 and the first rod member 36. The luffing rotator 560 is a device having upper and lower track segments that can be alternately rotated to align the track segments with the tracks in the second boom member or the first rod member, thereby transitioning the shuttle device across the luffing joint (i.e., the pivot joint) between the second boom member 34 and the first rod member 36.

[0499] The luffing rotator 560 is shown in detail in Figure 14I , comprising an electric servo motor 566 driving a reduction gearbox connected to a drive boss member 562 to which track segments 564, 565 are mounted. A driven boss 563, to which opposing track segments 564, 565 are mounted, is rigidly connected to the drive boss via a plate 561, and the luffing rotator 560 is rotatable about its mounting on the bulkhead 545.

[0500] The pivoting, or luffing, joint between the boom and the rod elements uses cylinders pushing aluminum links to provide 180 degrees of articulation. The boom has two hydraulic luffing cylinders with position encoder feedback. The luffing cylinders have integrated load-holding valves. These cylinders are connected by hoses to proportional valves in the machine base. A single proportional valve spool controls oil flow to both cylinders, allowing the boom to articulate and extend.

[0501] The bulkhead 545 is pivotally connected to the bulkhead 575 at the proximal end of the first rod member 36 via mounting ears 546, 547 disposed on opposite sides of the second boom member 34. The bulkhead 545 also includes connection points 548, 549 to which one leg of a dog-bone link 550 is pinned. The link 550 is connected between the second boom member 34, the first rod member 36 and the hydraulic luffing cylinder 532. Figure 15C Shown in more detail.

[0502] Figure 15A and 15B The first boom element 36 is shown connected to the luffing joint. It features a welded and post-weld heat-treated 6061-T6 aluminum fitting or bulkhead 575 bonded to a composite tube. The composite tube is constructed from four flat sandwich panels 571, 572, 573, and 574, bonded at the corners to aluminum extrusions or carbon fiber corner profile stacks. Ultra-high modulus pre-impregnated carbon fiber is used to achieve high stiffness at low weight. The luffing cylinder pin is double shear. One end of the hydraulic luffing cylinder 532 is pinned to an aluminum fitting 578 bonded to the tube and spaced apart from the bulkhead 575. The other end of the cylinder is connected to the head of a dogbone link 550, the second leg of which is connected to the bulkhead 575 at connection points 583 and 584. The bulkhead 575 is pivotally connected to the bulkhead 545 of the second boom element 34 via a pin extending through mounting ears 585 and 586. A composite link 579 supports the fitting 578 to reduce peel stresses on the panels 572.

[0503] The first mast element 36 includes a pair of inner rails, including a top rail 592 and a bottom rail 594, mounted offset from the side panels of the first mast element 36 via brackets 591, 593 connected to the bulkhead 575 of the first mast element 36. The inner rails of the first mast element 36 form a telescopic connection with the corresponding outer rails of the second mast element 38. The rails include upper and lower bosses 595, 596 configured to slidably interconnect with corresponding channels forming part of the rails of the second mast element, as described in further detail below. In the illustrated example, the rails of the first mast element 36 comprise a composite core inserted into the web portion of a C-shaped carbon fiber rail, with a common pair of rails used in all four locations (the same assembly is used for the left and right sides of the boom and mast).

[0504] like Figure 15D As shown, the first rod element 36 supports self-aligning linear roller bearing blocks 586, 587 (e.g., bearing slides) for the telescopic movement of the second rod element 38, which is telescoping within the first rod element. The bearing blocks 586, 587 are mounted to a fitting 585 mounted within the tube. The first rod element 36 typically includes linear roller bearing blocks at both the upper and lower portions of the rod element, along which the second rod element 38 slides. Wear pads 588, 589 are also typically mounted within the first rod element, over which the telescoping element slides. The wear pads serve as sacrificial wear parts and laterally position the second rod element 38.

[0505] The second rod element 38 is telescopically moved by a chain 581 driven by a sprocket 582 driven by a geared electric servo motor mounted on the first rod element 36. In the example shown, a pair of motors 579, 580 are mounted on opposite sides of the bulkhead 575, each motor driving a sprocket 582 and chain 581 on opposite sides of the rod element. The chain 581 is connected to the second rod element 38 by a fitting 597 (see FIG. Figure 16A ) is connected to the second rod element 38, which allows the chain tension to be adjusted. The chain drive forms an endless loop and acts as a winch to extend and retract the second rod element, providing a double chain arrangement for redundancy.

[0506] The second rod element 38 is as follows Figures 16A to 16C As shown in more detail, the second arm element 38, which telescopes within the first arm element 36, is also a composite tube constructed from four flat sandwich panels 601, 602, 603, and 604, bonded to aluminum or carbon fiber corner profiles at the corners. Ultra-high modulus pre-impregnated carbon fiber is used to achieve high stiffness at low weight. Bearing strips 620 and 621 are mounted in the same manner as the second boom element 34 for sliding engagement with bearing slides 586 and 587 mounted on the first arm element 36.

[0507] The second rod element 38 is telescopically movable by a chain 581 driven by a sprocket 582 driven by a geared electric servo motor 579, 580 mounted on the first rod element 36. The second rod element 38 includes a pair of adjustable chain connecting elements 608, 609 mounted on fittings 597 on both sides near the proximal end of the second rod element 36. Figure 16B Each chain 581 is disconnected at this point, with each end pinned to one of the chain connecting elements 608, 609 to connect each chain to the second rod element 38. The chain connecting elements 608, 609 are adjustable to vary the tension in each chain 581. Thus, the telescopic movement of the rod is driven by redundant dual chains and electric servomotors in a manner similar to that of the telescopic boom element.

[0508] The second rod element 38 has internally mounted tracks including a top track 612 (along which a loaded shuttle travels to the block laying robot) and a bottom track 614 (along which an empty shuttle returns), as shown in FIG. Figure 16B and 16CAs shown, the rails form part of a C-shaped carbon fiber channel profile, mounted to opposing inner surfaces of side panels 602 and 604. The profile captures U-shaped channel inserts 613 and 615 made of acetal near the upper and lower corners of its web. The web of the carbon fiber C-shaped rail profile includes a composite core to provide strength and reduce rail weight. In use, the rails of the first rod element 36 telescope within the rails of the second rod element 38. The bosses 595 and 596 mounted to the rails of the first rod element 36 are received within the channel inserts 613 and 615, which form part of the rails of the second rod element 38, to facilitate the telescopic movement of the respective rails.

[0509] At the distal end of the second rod element 38, there are aluminum bosses 605, 607 extending from opposing side panels 602, 604, by which the support tower of the block-laying robot 40 is pivotally connected to the second rod element 38. The boss 607 includes an arcuate rack 607 mounted thereon, which can mesh with a gear driven by a motor mounted on the support tower, allowing the support tower to articulate about the end of the second rod element 38 (for example, during the stowage of the boom system for transport and deployment for operation).

[0510] Block laying robot

[0511] Now refer to Figures 17A to 17M The block-laying robot 40 is described in further detail. The block-laying robot 40 forms part of a laying head and is suspended from a support tower 700, which is pivotally connected to the distal end of the second rod element 38. The block-laying robot 40 includes a laying arm 720 having an end effector 740 configured to receive a loaded shuttle. The end effector 740 moves to a block-laying position, at which point the shuttle releases the block and completes the laying motion. As will be described in further detail below, the empty shuttle is then raised from the lower track section of the end effector to the upper track section of the end effector, and the laying arm moves the end effector back to a neutral position, allowing the empty shuttle to move away from the end effector and allow another loaded shuttle to move in.

[0512] The support tower 700 of the block-laying robot 40 comprises a U-shaped body having a pair of arms 702, 704, with the support tower 700 being pivotally mounted to the end of the second rod element 38 via the arms 702, 704 for controlled rotation relative thereto. The arms 702, 704 extend upwardly at an oblique angle from a pivot with the second rod element and are connected by a bridge 706. In the illustrated example, the support tower 700 is a carbon fiber structure.

[0513] Arms 702 and 704 terminate at their lower ends in mounting ears 701, 707, and 703. The axis passing through ears 701 and 707 forms the pivot axis with the second rod element. Connecting plates 712 and 714 are mounted to bosses 605 and 606 on the end of the second rod element 38 and are rotationally connected to arms 702 and 704 of the support tower 700. The device for driving the support tower's rotation is housed in ear 703, which is offset from ear 707 on arm 702. A motor drives pinion 705 through a gearbox or Spinea reducer. Pinion 705 meshes with an arcuate rack 607 on boss 606 of the second rod element 38. Actuation of this drive device causes the support tower 700 to pivot about the end of the second rod element 38.

[0514] When the shuttle travels from the second rod element to the block laying robot 40, it is first received on the track of the shuttle rotator 780. The rotator 780 rotates about the pivot axis of the support tower 700 and is driven by a motor housed in the ear 701, which is connected to the bearing reducer 711 connected to the shuttle rotator 780. Figure 17G As shown, the shuttle rotator 780 includes a pair of spaced-apart side panels 781, 782 connected by a bridge plate 783. The ends of the side panels 781.1, 782.1 provide mounting ears that are pivotally connected to the support tower 700 near the connecting plates 712, 714. Upper and lower track sections 784, 786 are mounted to the side panels 781, 782 for receiving the shuttle thereon. In use, the loaded shuttle is driven from the second rod element 38 to the upper track 784 of the shuttle rotator 780. In this position, the shuttle and the block are in a normal position, with the block positioned above the shuttle. The shuttle rotator 780 is then rotated 180 degrees, so that the upper track 784 becomes the lower track, and the shuttle is inverted, with the block facing downward in the laying position. The inverted shuttle then travels, optionally via fixed track segments mounted on a support tower or auxiliary structure such as a rain cover structure 795, to the lower track of the end effector of the block-laying robot 40. Conversely, the empty return shuttle travels to the "lower track" 786 of the inverted shuttle rotator 780, flips back into the correct orientation, and then travels to the lower track 614 of the second rod element 38.

[0515] In the illustrated example, the block laying robot 40 is a spherical geometry robot, wherein the laying arm 720 is linearly extendable (radially) and controllably rotatable in roll and pitch via a yoke 722, while the end effector is controllable in roll, pitch, and yaw via a wrist mount. Thus, six degrees of freedom (6DOF) are provided for controlling the robot, enabling the end effector to be positioned with high precision in both position and attitude.

[0516] like Figure 17H and 17IAs shown, the block laying robot 40 includes a yoke 722 rotatably connected to a bridge 706 of a support tower 700. The yoke 722 is capable of rolling about a support tower mount 708 and is driven by a Spinea Twinspin bearing reducer driven by an electric servo motor (not shown) housed within the support tower mount 708. The laying arm 720 is slidably connected to a rotator 730, which is rotatably connected between the arms of the yoke 722. The rotator 730 is driven by a Spinea Twinspin bearing reducer driven by an electric servo motor 731 and is operable to control the pitch of the laying arm 720.

[0517] The outer surface of the rotator 730 is mounted with linear bearing blocks 725 and 726, which mesh with rails 721 and 723 mounted longitudinally on the rear surface of the laying arm 720. A motor with a brake 732 is mounted inside the rotator 730. This motor drives a pinion via a toothed belt, which meshes with a rack 724 mounted on the laying arm 720. This provides linear motion along the Z-axis, allowing the laying arm 720 to move up and down relative to the yoke 722.

[0518] Now refer to Figure 17J and 17K The wrist joint of the block laying robot 40 connecting the laying arm 720 to the end effector 740 is further described in detail. As previously described, the wrist joint provides roll, pitch, and yaw motions for the end effector 740. The end effector 740 includes a top plate 741, which is rotationally connected to the wrist via a Twinspin bearing reducer, which is driven by a pulley connected to a belt 738 driven by a motor 733 to provide rotation in the yaw direction. The wrist also includes a motor 734, which drives a belt 737 and a pulley to drive the Twinspin reducer to achieve rotation in the roll direction; the rotation in the pitch direction is driven by a motor 735 driving a belt 736 and a pulley to drive the Twinspin reducer to cause the main body 739 of the wrist to pitch.

[0519] In this example, end effector 740 is an attachment to the end of laying arm 720, used to manipulate the shuttle device to lay blocks. In the illustrated example, end effector 740 comprises a frame suspended from the wrist of laying arm 720, with a top plate 741 of the frame connected to the wrist. Top plate 741 is connected to opposing side plate members 743 and 744 and end plate 745. The frame forms a box-like structure with two open sides.

[0520] End effector 740 comprises upper and lower tracks, portions of which are rigidly fixed to the frame and portions of which are mounted on an elevator to enable raising and lowering of the track segments. The elevator is slidably connected to the frame and is used to lift the empty shuttle from the lower track segment to the upper track segment after the blocks are laid. The elevator comprises a crossbeam 746 extending across end plates 745. Linear bearing blocks mounted on crossbeam 746 are slidably connected to spaced rails 750 fixed to end plates 745, allowing crossbeam 746 to move up and down relative to end plates 745. The elevator is rigidly connected to lower track segments 757 and 758, which are spaced flange segments with L-shaped slots 759 between lower track segments 757 and 758. L-shaped slots 759 have no bottom flange.

[0521] The movable lower track sections 757 and 758 form part of the elevator and move up and down with the crossbar 746. The actuation assembly is provided in the form of a pneumatic cylinder 748 and a bellcrank 749 connected between the piston of the pneumatic cylinder 748 and the crossbar 746. The bellcrank 749 pivots as the piston retracts and retracts to raise or lower the elevator. The bellcrank 749 pivots about a pinned connection on the end plate 745 and is connected to a connecting rod 749.1, which is connected to the crossbar 746 of the elevator. Pneumatic actuation is preferred because the elevator requires greater speed and responsiveness in manipulating the shuttle mechanism and facilitates vertical compliance.

[0522] Additionally, during the laying motion, the pneumatic cylinder provides vertical compliance to the end effector by venting the plunger port, allowing the end effector to continue to descend slightly as the block contacts the surface.

[0523] The lower track comprises fixed track segments 755 and 756 mounted on the side panels 743 and 744 of the frame, and movable track segments 757 and 758 that move up and down with the elevator. The upper track comprises fixed track segments 751 and 754 mounted on the frame, and a movable track segment 752 that pivots relative to the side panels via a spring hinge. The movable track segment 752 has an arm 753 that pivots relative to the side panels via a spring hinge. This movable track segment 752 thus functions as a pivotable track segment similar to a trapdoor.

[0524] As the shuttle enters the end effector, its wheels engage the movable lower track elements 757, 758. After the laying operation is completed, the empty shuttle is lifted by the elevator via the movable lower track elements 757, 758. During the lifting process, the shuttle's wheels contact the pivotable upper track segment 752, causing it to flip up about its hinge. The lower track segments 757, 758 continue to rise until they align with the fixed upper track segments 751, 754, forming a continuous upper track. The shuttle is now located on a continuous upper track. At this point, the shuttle can be driven off the elevator's upper track. Once the shuttle is off track segments 757, 758, the elevator is lowered to allow another loaded shuttle to enter the end effector's lower track for the next laying operation. Note that as the wheels move from track segment 757 to track segment 754, track segment 752 flips downward, allowing the elevator track to be lowered. When the lay-up arm brings the end effector back to a neutral position (where the tracks of the end effector are aligned with the tracks of the support tower / auxiliary structure), the shuttle can be driven away from the end effector.

[0525] Now refer to Figures 18A to 18C An example of an adhesive application system 760 is described. The adhesive application system 760 is mounted on the support tower 700 of the block laying robot 40 and is used to apply adhesive to blocks before a shuttle device carrying blocks enters the end effector.

[0526] The adhesive application system 760 includes an adhesive tank 761 for storing adhesive. The tank can be of any suitable size and, in examples, can hold 10 L, 15 L, or 20 L of adhesive, such as one-part polyurethane (Suprasec, Durabond, Dryfix, Sikaflex), two-part polyurethane (Sikaflex), polyurea, epoxy (Araldite), polyester (Bondo), methacrylate (Plexus), cyanoacrylate (such as Super Glue, Loctite), acrylic (Gyprock Glue), silicone, thermoplastic polyurethane (TPU), and liquid nails.

[0527] Tank 761 is mounted on a bracket (not shown) supporting the tower arm. Adhesive flows by gravity through a dry quick-connect 765 (to prevent premature curing of the adhesive if the hose or tank is disconnected) into an inlet pipe 766 and into the inlet of a gear pump 764. An electric servo motor 762 drives gear pump 764 through a gear box 763. Adhesive is pumped from the outlet of gear pump 764 into an outlet pipe 767, to a nozzle assembly, and sprayed onto the lower surface of the block.

[0528] In the example shown, the nozzle assembly includes a pair of nozzles 768, which are angled by slots in a guide plate 770 secured to a nozzle bracket 769. A drip collector 771 may be mounted on the nozzle bracket 769 below the nozzles 768 to collect dripping adhesive.

[0529] The position of the nozzle assembly is adjustable depending on the type of block. Servomotors are used to position the block horizontally and vertically to the correct spray width and height. A vertical servo motor 772 drives a trapezoidal threaded rod 773, while a horizontal servo motor 778 drives a pinion gear that meshes with a rack 777. A carriage 775 is slidably connected to a vertical track 774 and configured so that when servo motor 772 is actuated, the carriage 775 and nozzle assembly adjust in height. The nozzle assembly is connected to another track 776 and rack 777. The carriage 775 is mounted to a linear bearing block, which is connected to the track 776. Actuation of a servo motor 778 mounted on the carriage 775 causes the track 776 and nozzle assembly to move laterally.

[0530] The lateral position of the nozzle should be aligned with the rib or surface shell of the block. It is contemplated that the lateral position of the nozzle may be fixed for each block type. The pump motor 762 is controlled to synchronize the application of glue with the movement of the shuttle carrying the block past the nozzle outlet. A sensor may detect the beginning and end of the block as the shuttle passes the nozzle outlet, which triggers the pump to apply glue. Alternatively, the position of the shuttle in the machine may be used to trigger the pump to apply glue based on the time and distance traveled by the shuttle as it reaches and passes the nozzle outlet.

[0531] To achieve a repeatable adhesive signature, a fixed-displacement gear pump applies a precise amount of adhesive to the blocks. A camera and lighting system images the adhesive signature on each block, and an image processor determines the amount of adhesive applied, enabling measurement and / or verification of the amount of adhesive applied to each block.

[0532] Other examples of adhesive application systems suitable for use with the machine are described in the applicant's co-pending applications WO2022 / 006635 and WO2020 / 047573.

[0533] Saw module

[0534] Now refer to Figures 19A to 19I An example of an optional saw module 800 that can be installed in the machine base is shown. The illustrated saw module 800 is a multifunctional saw that can cut blocks square to length, bevel cuts, gable bevel cuts, and blocks to reduced height. Cutting can be performed on blocks up to 600 x 300 x 400 mm (length x width x height).

[0535] In this example, a gantry saw was set up with a wet diamond blade of 1000 mm diameter (water cooled to remove dust and lubricate the blade to maximize blade life).

[0536] The saw module 800 includes a base frame 801 and a gantry saw, which includes a gantry track 810 mounted on the base frame 801 and a gantry frame 812 connected to a saw blade 811 and a motor. The gantry frame 812 is slidably mounted on the gantry track 810 and translates along the X direction. Figure 19C and 19D The middle gantry frame 812 and saw blade 811 are positioned in their initial positions. When activated (e.g., by a chain drive), the gantry frame 812 and saw blade 811 move to the cutting position. The frame adjacent to the gantry track 810 includes a sliding door 803. This door opens when the transfer robot loads blocks into the saw, providing clearance for the boom or gantry of the transfer robot 60. Once the transfer robot 60 moves away, the sliding door 803 closes again, enclosing the saw blade 811 during cutting.

[0537] The saw module 800 includes a loading area 802 with a slotted cutting deck 806 positioned adjacent to the floor of the base frame 801. Blocks to be cut are placed on the cutting deck, from which they are subsequently retrieved by a transfer robot. Once a block is placed in the loading area 802, it is manipulated to move it to the desired cutting position and orientation, depending on the type of cut required.

[0538] To achieve this control, two block translation mechanisms are provided. The first block translator 820 (i.e., Y-direction translator) is provided near the cutting plate 806 and can move the blocks in a direction orthogonal to the cutting direction of the saw blade 811. The details of the first block translator 820 are shown in FIG. Figure 19E and 19F shown.

[0539] The first block translator 820 includes an elongated base 821 on which a pair of rails 822 and 823 are mounted. A first carriage 826 is slidably coupled to the rails 822 and linearly moved along the base 821 by a servo-pneumatic drive 825. A first arm 827 is mounted on the first carriage 826, and a first paddle 828 is rotatably connected to the end of the first arm 827. The first paddle 828 rotates about the end of the first arm 827 via a Twinspin driven by a motor 829 mounted at the end of the first arm 827. A second carriage 830 is slidably coupled to the rails 823 and linearly moved along the base 821 by a servo-pneumatic drive 824. A second arm 831 is mounted on the second carriage 830, and a second paddle 832 is rotatably coupled to the end of the second arm 831. The second paddle 832 rotates about the end of the second arm 831 via a Twinspin driven by a motor 833 mounted at the end of the second arm 831.

[0540] The paddles 828, 832 are generally rectangular plate-like structures suitable for pushing blocks along the cutting plate 806. However, the first paddle 828 is notched to allow the fingers of the block turning mechanism 840 to pass through, which will be referred to below. Figure 19G and 19H Detailed description.

[0541] Thus, the first block translator 820 is capable of pushing the block along the cutting plate 806. When the block is loaded into the loading area 802 of the saw module 800, the first paddle 828 is used to push the block, positioning it in the Y-axis direction to the correct position for the saw blade 811 to make the corresponding cut. After the block is cut, the second paddle 832 is used to push the cut block back in the opposite direction to the loading area 802 so that the transfer robot can pick it up and remove it from the saw module 800.

[0542] As described above, paddles 828 and 832 are capable of independent linear translation and rotational motion. To perform a bevel or gable cut, the first paddle 828 contacts the block and rotates to adjust the angle of the block on the cutting plate 806 to the desired angle for the saw to perform the bevel cut. Once the cut is complete, the second paddle 832 can be used to rotate the cut block back to an upright position for easy pickup.

[0543] like Figure 19C 、 19D As shown in FIG19I, a second block translator 860 may also be provided. The second block translator 860 is configured to push the block along the X-axis direction of the saw (i.e., the direction of travel of the saw blade 811). The second block translator 860 includes a push plate 862 driven by a pneumatic cylinder 864 and a guide rod (see FIG19I). Figure 19I ), guide rods cause push plate 862 to reciprocate across cutting deck 806. Typically, saw module 800 includes a rigid fence 804 positioned adjacent to the cutting deck along the saw's Y-axis (orthogonal to the saw blade's cutting direction). Second block translator 860 is used to push blocks against fence 804, providing support for the blocks during cutting. Second block translator 860 can remain extended during the cutting process, effectively clamping the blocks against the fence and preventing them from moving.

[0544] like Figure 19G and 19H As shown in more detail, saw module 800 also includes a block rotation mechanism 840. Located in loading area 802, block rotation mechanism 840 is used to flip a block standing upright on its base so that it stands on its side. In this manner, the block can be positioned on its side, allowing saw blade 811 to cut along its height (i.e., horizontally, rather than vertically along its length). This mechanism can also be used for gable miter cuts, with blades 828, 832 rotating the block.

[0545] Block rotation mechanism 840 includes a finger assembly 841, which comprises a plurality of L-shaped fingers spaced apart and rigidly connected to a rotating rod 844. Each L-shaped finger comprises first and second elongated members 842 and 843 extending orthogonally from rotating rod 844. Finger assembly 841 is rotatably mounted on bushings 845 and 846 connected to opposite ends of rotating rod 844. Bushings 845 and 846 are connected by a bracket 847 and are capable of translation along guide rods 848 and 849. A first pneumatic cylinder 850 controls the translation of block rotation mechanism 840 along the Y-axis.

[0546] A second pneumatic cylinder 851 is connected to a lever arm 852 that is connected to the rotating rod 844. Actuation of the pneumatic cylinder 851 causes the finger assembly 841 to rotate. The range of rotation is limited by stops 853, 854 that contact the lever arm 852.

[0547] Finger assembly 841 aligns with slots in cutting board 806 and first paddle 828, allowing the finger assembly to pass freely through these components. Typically, some of the fingers of the finger assembly are positioned horizontally below cutting board 806, while others are positioned vertically across cutting board 806. To rotate a block, the rod of first pneumatic cylinder 850 retracts, translating finger assembly 841. This simultaneously causes lever arm 852 to pivot and rotate finger assembly 841, positioning the vertically positioned finger members midway along cutting board 806. The block is then placed on cutting board 806, between the vertically positioned finger members and first paddle 828. Next, the rod of second pneumatic cylinder 851 retracts, pivoting lever arm 852 and causing finger assembly 840 to flip the block onto its side. Once the cut block is rotated back to its upright position, the same process is reversed, with the block returned to the loading area for pickup.

[0548] Typically, the saw module 800 also includes a waste chute to discharge waste chips, and another block rotation mechanism for automatically dumping waste chips into the waste chute.

[0549] hydraulic system

[0550] The machine uses hydraulic drive to move large loads.

[0551] In one example, the machine has a hydraulic system that is used to operate the outriggers deployment, boom raising and lowering, and luffing.

[0552] The hydraulic system comprises a primary variable displacement piston pump that can be driven by either a diesel engine or an electric motor. In diesel engine drive mode, the diesel engine drives a transmission-mounted power take-off (PTO), which is connected to a long drive shaft and in turn drives the hydraulic pump and electric motor / generator to generate electricity.

[0553] In motor-drive mode, shore power (such as on-site power at a construction site) drives the electric motor / generator, which in turn drives the hydraulic pump. In this mode, the PTO is isolated from the rotating drive shaft by a clutch because the PTO bearings and internal clutch plates are designed to not work when the motor is stationary and the drive shaft is rotating. They require pressurized oil provided by the transmission for lubrication, and the transmission must be driven by the engine to provide oil pressure.

[0554] The machine uses a proportional hydraulic system, and the pump can operate in load sensing (LS) mode or constant pressure (CP) mode. Each function is equipped with only one proportional control valve.

[0555] The hydraulic system incorporates comprehensive safety features to provide a CAT3 safety architecture, including monitored double block and bleed valves for pressure isolation, and load-holding valves mounted on associated cylinders.

[0556] The movement of the outriggers is controlled by the machine operator via proportional valves actuated by direct levers. This significantly simplifies and improves the operability and safety of the outriggers compared to the PLC-controlled outriggers used in the applicant's earlier machines.

[0557] Hydraulic components are combined wherever possible into a single module that includes the motor / generator, pump, cooler, proportional control valve, filter and oil tank.

[0558] electrical system

[0559] The electrical system includes a generator driven by the truck's diesel engine. The electrical system can be powered by either the diesel generator or shore power. As mentioned above, the hydraulic pump can be driven by an electric motor, allowing the machine to operate entirely electrically and hydraulically without the diesel engine running.

[0560] The electrical system is distributed among the modules. The modules are designed to operate as independently as possible. The main power distribution unit is located in an electrical cabinet mounted on the machine base, with an additional distribution board.

[0561] The generator can function as a motor to power a hydraulic pump. The generator is connected to a Siemens variable speed drive (VSD) for motor operation and an inverter for generator operation. In one example, the motor's servo drive is an Elmo Twitter drive, which is more compact than the Whistle and Guitar drive and includes Functional Safety over EtherCAT (FSOE).

[0562] The individual modules, drives, and input / output (IO) communicate via EtherCAT. Multiple Beckhoff TwinCAT masters run on multiple IPCs. Where feasible, the modules are connected via hybrid cables that carry 170VDC, 24VDC, and EtherCAT communication in a single cable. In one example, the connectors are bayonet-type. Additionally, Xingterra Power Line Communication, carried over the 24VDC power distribution lines, provides an additional Ethernet communication channel.

[0563] A cooling system can also be installed in the base, providing chilled water to cool the electronics. This system typically includes a water tank, pump, and refrigeration chiller. The machine typically connects cooling water piping to the electrical enclosure and cabinets. For areas of the enclosure where cooling water is inconvenient to supply, thermoelectric (Peltier) coolers are used to provide cooling.

[0564] control system

[0565] In one example, the machine uses a soft programmable logic controller (PLC) and computer numerical control (CNC) architecture provided by Beckhoff. The B&R TwinCAT control system includes TwinCAT PLC, TwinCAT CNC, and TwinSAFE components.

[0566] In one example, the machine uses a TwinCAT PLC software programmable logic controller (PLC). This PLC is implemented as software on an IPC. The PLC includes numerical control (NC) functionality to support simple point-to-point motion. The PLC handles input / output (IO) and logic sequencing.

[0567] The machine uses eight TwinCAT 3 PLCs for each shuttle unit and an Arduino Raspberry Pi CM4 PLC running PiCAT with an IgH EtherCAT master. Each module operates as independently as possible and communicates with a supervisory PLC running on a supervisory IPC. The supervisory IPC runs a database server that exchanges information with the supervisory PLC.

[0568] The module PLCs communicate with the supervisory PLC through an interface that shares common elements but also includes customizable elements as needed. Communication is based on the Ethernet MQTT protocol carried by Xingterra Power Line Communications (running on the 24V power distribution system). Real-time data is transmitted via EtherCAT.

[0569] The CNC-enabled module runs or generates the required G-code programs. This machine uses TwinCAT CNC software. CNC is implemented as software on an industrial personal computer (IPC). The CNC functions execute complex movements. The machine is modular in design, and the TwinCAT CNC-enabled modules include a transfer robot, boom, and block-laying robot.

[0570] The machine uses the applicant's core dynamic stabilization technology (DST), which corrects the robot's posture and ensures that the end effector is accurately positioned and oriented in the working coordinate system, regardless of the position and orientation of the robot base and the deformation or dynamic movement of the robot structure. DST measures the six degrees of freedom (6DOF) position and orientation of the support tower (or the end effector itself) of the block laying robot. The position and orientation are measured by data received from a laser tracking system and optionally from an inertial measurement unit (IMU). In one embodiment, the position and orientation data are input into a control system, which combines the measurement data with a state model through a Kalman filter. The control system compares the actual position and orientation with the desired position and orientation, calculates the motion correction amount and applies it by the block laying robot to minimize positioning errors, thereby stabilizing the end effector in real time. DST enables construction robots with long booms to stabilize the end effector at their ends in complex outdoor environments.

[0571] Reference Figure 20 , which shows an example of a schematic diagram of a control system for controlling a shuttle queue in a block laying robot. The control system includes a monitoring IPC (Industrial Personal Computer) 901, which runs a soft monitoring PLC (Programmable Logic Controller) 904 (such as B&R TwinCAT PLC) implemented as software. The monitoring PLC 904 contains a central controller 902, which is used to manage the work plan that the block laying robot needs to perform in a specific construction. The central controller 902 issues job requests to the modules and coordinates the movement of the shuttle and the track. The central controller 902 issues job requests to the shuttle queue controller 903, which is a software module implemented in the form of a collection of TwinCAT PLC code objects (function blocks, functions, etc.) running on the monitoring PLC 904.

[0572] The shuttle queue controller 903 receives instructions from the central controller 902 indicating shuttle job requests and provides shuttle status information to the central controller 902. Furthermore, the shuttle queue controller 903 sends instructions to the shuttles to perform jobs requested by the central controller 902 and receives status information from each shuttle 910. Thus, the shuttle queue controller 903 is responsible for managing the shuttle network and coordinating its movement with the central controller 902, while the central controller 902 is responsible for task sequencing and track movement.

[0573] The shuttle queue controller 903 communicates with each shuttle device 910 in the system via a wireless communication network such as Wi-Fi. Data between the shuttle queue controller 903 and each shuttle device 910 is transmitted via an MQTT proxy server. An MQTT proxy server is an intermediary entity that facilitates communication between MQTT clients. Specifically, the MQTT proxy server receives messages published by clients, filters them by topic, and distributes them to subscribers. Therefore, the MQTT proxy server supports a publish / subscribe communication model, making it an efficient and scalable protocol for shuttle device communication in a fleet of up to 30 shuttle devices.

[0574] The monitoring IPC also includes an SQL database server 905, which includes a shuttle manager database 906, which is used by the queue controller 903 to manage the movement of the shuttle queue and store variables such as shuttle location, last known reference point, and shuttle manager database 906 charge status.

[0575] exist Figure 20 In the illustrated example, the shuttle 910 includes an electronic processing device 911, which forms part of a processing system comprising the electronic processing device 911, such as a microprocessor; memory 912; input / output (I / O) devices 123, such as I / O cards for sensors 916 (e.g., proximity sensors and collision avoidance sensors) and actuators 917, such as grippers and motors; and one or more interfaces 914, interconnected via a bus 915. The interface 124 can be of any form, including a wireless transceiver (enabling the shuttle 910 to communicate with the shuttle fleet controller 903 via a wireless communication network, such as Wi-Fi), a universal serial bus (USB) port, an Ethernet port, and the like. In use, the processing device 911 receives instructions from the shuttle fleet controller 903 via the interface 914, which are optionally stored in the memory 912. The processing device 911 then processes the signals according to the instructions (e.g., in the form of software instructions) stored in the memory 912, thereby controlling the shuttle and performing gripping and motion tasks, such as shuttle loading, datum positioning, travel, and placement.

[0576] However, this is merely an example, and it should be understood that the electronic processing device 911 may include any form of electronic processing device capable of receiving and processing signals from the shuttle fleet controller 903. Thus, the electronic processing device can include a microprocessor, a microchip processor, a logic gate configuration, firmware (optionally associated with a logic implementation such as an FPGA (field programmable gate array)), a suitably configured computer system, or any other electronic device, system, or device capable of receiving and processing signals. In one example, each shuttle device includes an Arduino Raspberry Pi microcontroller.

[0577] The processing device 911 is the main controller that implements most of the local control tasks of the shuttle device. In some embodiments, the shuttle device also includes a sub-controller for controlling the power supply of the main controller and braking the drive motor when the main controller is unavailable.

[0578] It should be understood that the processing device 911 is configured to wirelessly receive instructions indicating motion requests from the shuttle device queue controller 903, control the drive system on the shuttle device to execute the motion request, and wirelessly return status information indicating at least part of the status of the motion request to the shuttle device queue controller 903.

[0579] Furthermore, the processing device is configured to control the opening and closing of the clamps based on commands received from the shuttle queue controller. For example, the shuttle may receive a command to move to a loading location in the storage area and, upon reaching the loading location, open its clamps to prepare to receive a block of a specified size. It then receives a command to complete the loading operation and close the clamps to clamp the block. Thus, the processing device 911 is configured to perform one of the following operations: open the clamps to a specified width; close the clamps to a specified width and clamp the block with a specified force.

[0580] When in use, the shuttle device travels along the track between the base and the block laying robot. The track includes a sending track and a return track to accommodate the shuttle device to go to the block laying robot and return to the base. In one example, the track includes fixed and movable track segments, wherein the movable track segment includes a translation or rotation track (such as the elevator and translator in the storage area and turntable, the tower, the luffing mechanism and the shuttle device rotator at the laying head). When the shuttle device travels in the system, it continuously sends status information indicating its position in the track system to the shuttle device queue controller 903, so that the central controller 902 can coordinate the movement of the shuttle device and the movable track. If the track is not ready to receive the shuttle device, it will request a stop or wait command, causing the shuttle device to slow down and stop until further instructions are received. If the movable track segment is ready to receive the shuttle device, the shuttle device will be commanded to continue traveling along one or more track segments to the final destination.

[0581] Typically, each shuttle has wheels that engage the track segments, and a drive system includes one or more motors that drive the wheels. The processing unit 911 sends signals to the motor drivers, causing the motors to rotate, thereby moving the shuttles along the track according to the instructions of the shuttle fleet controller 903.

[0582] Each shuttle includes one or more sensors 916, including sensors for referencing the shuttle's position on the track. These sensors detect trigger targets distributed along the track. Detection of the targets causes one or more processing devices 911 to capture the encoder position of the shuttle's drive motor. As previously described, the one or more sensors can be one of the following: an inductive proximity sensor on each shuttle that detects a metal trigger target mounted along the track; or an optical sensor on each shuttle that detects a reflective trigger target mounted along the track.

[0583] Typically, a shuttle 910 reports its position to the shuttle queue controller 903 based on the distance traveled relative to the last position reference point it captured. As previously described, each position reference point has a unique identifier, and a motion request indicating movement from a current position to a final position includes a series of position reference identifiers, including the starting position reference identifier, the requested final position reference identifier, and any intermediate position reference identifiers that the shuttle will detect between the current position and the final position. As the shuttle executes its motion request, each position reference point it senses is stored in memory 912 and communicated to the shuttle queue controller 903, allowing the shuttle queue controller 903 to track every shuttle in the network.

[0584] The processing device 911 is also configured to manage the charging of the batteries on the shuttles and report charging status information to the shuttle fleet controller 903. During each cycle in the machine, the shuttles are typically charged while in a storage area that has charging rails that contact the power pickup on each shuttle.

[0585] When traveling in the system, each shuttle device uses an anti-collision sensor to monitor any objects in its path (in front and behind), and the processing device 911 is configured to: monitor the signals received from the anti-collision sensor; control the drive system to modify the speed or brake the motor based on the received signal to ensure that collisions with other shuttle devices or objects are avoided.

[0586] Reference Figure 21 , which shows a schematic diagram of a control system for controlling a block laying robot.

[0587] In this example, as previously described, central controller 902 communicates with shuttle queue controller 903, which in turn communicates wirelessly with shuttle queue 910. Central controller 902 also communicates with each module controller 930, 940, 950, 960, and 970 within the machine, which receive instructions and execute commands locally within each module. For simplicity, this diagram does not show all modules; only a subset is depicted for illustrative purposes. As shown, the control architecture is distributed, with each module controlling its own functions independently of the others and executing job requests from central controller 902. Consequently, the system is highly modular, allowing modules to be interchangeable without impacting the rest of the system.

[0588] As previously mentioned, the control system includes a supervisory IPC (Industrial Personal Computer) running a software-implemented supervisory PLC (Programmable Logic Controller) such as a B&R TwinCAT PLC. The supervisory PLC includes a central controller 902 for managing the work plan that the robotic block laying machine needs to perform in a particular construction.

[0589] exist Figure 21 In the illustrated example, central controller 902 includes an electronic processing device 921, which forms part of a processing system comprising an electronic processing device 911 (e.g., a microprocessor), memory 921, input / output (I / O) devices 923, and one or more interfaces 924, interconnected via a bus 925. Interface 924 can be of any form, including a Universal Serial Bus (USB) port, Ethernet, etc. In one example, central controller 902 communicates with each module via EtherCAT to enable real-time communication. In use, processing device 921 sends instructions indicating job requests required for sequencing construction tasks to module controllers 930, 940, 950, 960, 970 and shuttle queue controller 903 via interface 924, and receives signals indicating status information from each module, optionally storing the information in memory 912 or a database server (not shown). Processing device 921 then processes the received signals according to instructions (e.g., in the form of software instructions) stored in memory 922, thereby controlling the modules and shuttles to ensure proper sequencing of jobs.

[0590] In one example, the control system includes one or more electronic processing devices configured to: control a shuttle device to move from a base through a boom to a block laying robot, thereby transporting blocks to the block laying robot; control the boom to move the block laying robot to a desired position for laying blocks; control the block laying robot to perform the following operations: position an end effector near the distal end of the boom to receive the shuttle device; position the shuttle device near a block laying position so that the shuttle device releases the block to complete the laying of the block; position the end effector near the distal end of the boom to allow the shuttle device to return to the boom; and control the shuttle device to return an empty shuttle device along the boom to the base.

[0591] In one example, the one or more processing devices include: a central controller 902 configured to manage a plan of operations to be performed by a robotic block laying machine in a particular construction project; and a shuttle queue controller 903 that communicates with the central controller 902 (including receiving instructions indicating shuttle operation requests and providing shuttle status information to the central controller 902) and wirelessly communicates with each shuttle 910 in the queue (including sending instructions to the shuttle to perform the operations requested by the central controller 902 and receiving status information from the shuttle 910).

[0592] As previously described, the one or more processing devices further include at least one shuttle controller provided in each shuttle device, the at least one shuttle controller being configured to control the shuttle device 910 according to commands from the shuttle device queue controller 903. The at least one shuttle controller is configured to control the drive system on the shuttle device to execute motion requests, control the opening and closing of the clamps according to instructions received from the shuttle device queue controller 903, manage the charging of the battery on the shuttle device, and report charging status information to the shuttle device queue controller 903.

[0593] At least one shuttle controller provides status information to the shuttle fleet controller 903, including information from one or more sensors used to reference the position of the shuttle on the track. These sensors detect trigger targets distributed along the track, and upon detection, the shuttle controller captures the encoder position of the shuttle drive motor. Furthermore, the control system may include sensors that detect the position of the shuttle within the machine, and one or more processing devices may be configured to control the shuttle based on signals from the sensors. In one example, sensors are distributed along the track to confirm the presence of the shuttle at a specified location, and these sensors can transmit data to the central controller 902 via EtherCAT.

[0594] The central controller 902 in the control system may also include a boom controller 930 and a block laying robot controller 940. The boom controller 930 is configured to control the boom according to commands from the central controller 902, and the block laying robot controller 940 is configured to control the block laying robot according to commands from the central controller. The boom controller 930 controls one or more boom actuators 931 and 932 (in the form of hydraulic cylinders and servo motors that control lifting, luffing, and extension and retraction of the boom and rod) to move the boom to the desired position. Typically, the boom is controlled by a CNC, and the boom DST stability is controlled by a PLC. The block laying robot controller 240 controls one or more laying arm actuators (in the form of servo motors that control each axis of the block laying robot). Typically, the block laying robot is controlled by a CNC, and the laying arm DST stability is controlled by a PLC.

[0595] The one or more processing devices are further configured to control at least one transfer robot to perform the following operations: pick individual blocks from a bag of blocks; and transfer each block to a corresponding one of a plurality of shuttle devices located at a loading position on the machine base. In one example, a pair of transfer robots are provided to concurrently pick blocks from a bag of blocks and transfer them to the shuttle devices. The one or more processing devices include transfer robot controllers 950, 970 configured to control actuators 951, 952, 971, 972 (e.g., servo motors of the transfer robot) of the transfer robot in response to commands from the central controller 902. Typically, the transfer robot is controlled by CNC, and the fixture control is implemented by NC.

[0596] The one or more processing devices are further configured to control a plurality of bag conveyors that move the building block bags in the machine base forward to the empty bag station. The one or more processing devices include a bag conveyor controller 960 configured to control bag conveyor actuators 961, 962, and 963 to move the bag conveyors according to commands from the central controller 902. Typically, the bag conveyors are controlled by a PLC / NC.

[0597] Although not shown, one or more of the processing devices may also include: at least one shuttle elevator controller configured to move the shuttle between storage area levels in response to commands from the central controller; and a shuttle translator controller configured to move the shuttle into and out of the storage area. Furthermore, a turntable rotation controller configured to control the rotation of the turntable about the tower; and one or more turntable rotator controllers configured to control the rotation of the turntable rotator to respectively effectuate the transfer of the shuttle between the turntable and the tower and translator, respectively. The pallet ejector and saw module may also have their own controllers to execute commands from the central controller 902.

[0598] In summary, the foregoing describes a robotic block laying machine and its various features and configurations, providing a variety of different arrangements that may be used independently and / or in combination.

[0599] In one broad form, one aspect of the present invention is directed to a robotic block laying machine for constructing a block structure, the robotic block laying machine comprising:

[0600] a) a base configured to receive a building block;

[0601] b) Boom;

[0602] c) a tower rotatably mounted to the base about a boom slew axis, the tower supporting the boom and the boom being pivotally connected to the tower;

[0603] d) a block laying robot provided at the distal end of the boom for laying blocks;

[0604] e) a plurality of shuttles, wherein each shuttle is configured to receive a block and transport it along the boom from the base to the block-laying robot; and

[0605] f) At least one transfer robot configured to pick up one of the building blocks and transfer it to the shuttle.

[0606] In one broad form, one aspect of the present invention is directed to a transfer robot for a block-laying robot for constructing a block structure, wherein the transfer robot is configured to pick up a single block and comprises:

[0607] a) an upright support slidably mounted to the frame for longitudinal travel thereof;

[0608] b) a beam having one end slidably mounted to the upright support for movement up and down the upright support;

[0609] c) a carriage slidably mounted to the crossbeam for lateral movement; and

[0610] d) An arm slidably mounted to the carriage for up and down movement, the distal end of the arm including a gripping mechanism for picking up a block.

[0611] In one broad form, one aspect of the present invention is directed to a shuttle sequencing system for a block-laying robot for constructing a block structure, the sequencing system being configured to store shuttles for transporting blocks along a boom of the block-laying robot, comprising:

[0612] a) Shuttle storage area, which includes multiple layers of tracks on which the shuttles travel and are stored when not in use;

[0613] b) means for moving the shuttle to tracks on different levels of the storage area; and

[0614] c) A shuttle translator configured to move the shuttle into and out of the storage area.

[0615] In one broad form, one aspect of the present invention is directed to a shuttle sequencing system for a block-laying robot for constructing a block structure, the sequencing system being configured to store shuttles for transporting blocks along a boom of the block-laying robot, comprising:

[0616] a) Shuttle storage area, which includes multiple layers of tracks on which the shuttles travel and are stored when not in use;

[0617] b) a charging system for charging the shuttle while it is in the storage area; and

[0618] c) A shuttle translator configured to move the shuttle into and out of the storage area.

[0619] In one broad form, one aspect of the present invention is directed to a shuttle datum assembly for a block-laying robot for constructing a block structure, the datum assembly being configured to align blocks on a shuttle so that the shuttle can transport the blocks via a boom of the block-laying robot, comprising:

[0620] a) Track;

[0621] b) Shuttle device;

[0622] c) a reference plate laterally spanning the track and movably mounted longitudinally relative to the track so that the reference plate can be set at a reference position and when the shuttle travels along the track to the reference position, the blocks engage the reference plate and are pushed to the reference position on the shuttle.

[0623] In one broad form, one aspect of the present invention is directed to a block laying robot for constructing a block structure, comprising:

[0624] a) base;

[0625] b) Boom;

[0626] c) a block laying robot disposed at the distal end of the boom for laying blocks;

[0627] d) a plurality of shuttle devices, each configured to receive a block and transport it along the boom from the base to the block-laying robot;

[0628] e) a shuttle translator configured to move the shuttle into and out of a shuttle storage area in the base;

[0629] f) a tower rotatably mounted to the base about a boom slew axis, the tower supporting the boom and the boom being pivotally connected to the tower; and

[0630] g) a turntable concentrically aligned with the boom slew ring at the base of the tower, the turntable being rotatable about the tower and comprising a plurality of radially spaced turntable rotators, each rotator being configured with two pairs of tracks for:

[0631] i) Receive the loaded shuttle from the shuttle translator and drive it to the tower track

[0632] paragraph; and

[0633] ii) Receive the empty shuttle from the tower track segment and travel it to the shuttle translator.

[0634] In one broad form, one aspect of the invention is directed to a boom of a block-laying robot for constructing a block structure, the boom comprising two pairs of telescopic boom and rod elements having at least one pivot joint therebetween, and each element including a track segment extending along its length, the track segment being configured to allow a shuttle to travel along the boom.

[0635] In one broad form, one aspect of the present invention is directed to a block laying robot for constructing a block structure, the robot being disposed at a distal end of a boom and comprising: a laying arm; and an end effector comprising: a frame; first and second spaced-apart end effector tracks mounted to the frame and configured to align with corresponding first and second tracks in the boom; and an elevator slidably mounted to the frame and configured to transfer an empty shuttle from the first track to the second track to allow a fully loaded shuttle to be received from the first track and an empty shuttle to be returned to the second track.

[0636] In a broad form, one aspect of the present invention is directed to a block-laying robot for constructing a block structure, comprising: a base; a boom extending from the base; a plurality of shuttles, each configured to: receive a block; travel along the boom to transport the block; and a block-laying robot disposed at a distal end of the boom, the robot configured to: receive the shuttle from the boom; and position the shuttle near a block-laying location so that the shuttle can release the block and complete the laying.

[0637] In a broad form, one aspect of the present invention is directed to an adhesive application system for a block-laying robot for constructing a block structure, the system being configured to be supported proximate to the block-laying robot (at a distal end of a boom), comprising: at least one adhesive tank; a nozzle outlet configured to spray adhesive onto a lower surface of a block; a supply line extending from the at least one adhesive tank to the nozzle outlet; and a motor driving a gear pump for pumping the adhesive through the supply line.

[0638] In a broad form, one aspect of the present invention is directed to a shuttle device for a block-laying robot for constructing a block structure, configured to transport blocks via a boom, comprising: a frame; a clamp assembly configured to receive and clamp blocks; and a wheel assembly connected to the frame to engage with a track, the wheel assembly including at least one driven wheel assembly connected to a drive motor so that the shuttle device can travel along the track and transport blocks via the boom.

[0639] In a broad form, one aspect of the present invention is directed to a vehicle including a block-laying robot for constructing a block structure, comprising: a vehicle chassis; a support frame mounted to the chassis; and a block-laying robot mounted from the support frame, the robot comprising: a base; a boom; a tower rotatably mounted to the base about a boom rotation axis, supporting the boom and pivotally connected to the tower; a block-laying robot disposed at a distal end of the boom; a plurality of shuttle devices, each configured to receive a block and transport it along the boom to the laying robot; and a leg system for stabilizing the vehicle during operation, the system depending from the support frame and including front folding legs arranged on opposite sides of the vehicle, the folding legs pivotally connected to foot pads, the legs being unfolded at an angle to the ground when in use.

[0640] In a broad form, one aspect of the present invention is directed to a block-laying robot for constructing a block structure, comprising: a base; a boom; a tower rotatably mounted to the base about a swing axis of the boom, supporting the boom and pivotally connected to the tower; a block-laying robot disposed at a distal end of the boom; a plurality of shuttle devices, each configured to receive a block and transport it along the boom to the laying robot; and a block-cutting saw module located in the machine base, the saw module comprising: a base frame; a gantry saw comprising: a gantry track mounted to the base frame; a saw blade and a motor connected to the saw blade. The machine comprises a gantry frame which is slidably mounted to the gantry track for translation along the same; a loading area having a cutting plate arranged near the floor of the base frame, on which blocks to be cut are placed and from which the blocks are retrieved after cutting; a first block translator adjacent to the cutting plate which can move blocks in a direction orthogonal to the cutting direction of the saw blade; a baffle mounted beside the cutting plate, against which the blocks at least partially rest when in use for support during cutting; and a second block translator adjacent to the cutting plate which can be moved in the cutting direction of the saw blade for: pushing the blocks against the baffle; or clamping the blocks to the baffle during cutting.

[0641] In one embodiment, the saw module includes a block rotation mechanism that can change the posture of a block placed on the cutting board by 90 degrees, the mechanism comprising: a finger assembly, including a plurality of spaced L-shaped fingers, rigidly connected to a rotating rod rotated by an actuator; and a rotating rod, the opposite end of which is connected to a bushing that can slide along a guide rod so that the finger assembly can be translated in the same direction as the first block translator. In use, the finger assembly is translated under the block and then rotated to rotate the block to a different posture.

[0642] In one embodiment, the block rotation assembly is located adjacent to a cutting board having slots that align with the finger assemblies, allowing the fingers to freely translate and rotate across the cutting board to manipulate the blocks.

[0643] In one embodiment, the first block translator includes first and second spaced apart arms independently slidable along the base, the arms extending above the cutting deck and having a paddle attached to each distal end for urging the block along the cutting deck.

[0644] In one embodiment, each paddle is rotatable, allowing the angle of the paddle relative to the cutting board to be changed so that the blocks can be tilted for gable and bevel cuts.

[0645] In one embodiment, the blocks are loaded to and retrieved from the loading area by a transfer robot.

[0646] In one embodiment, the saw blade is a water-cooled diamond blade for dust removal and blade lubrication.

[0647] In this specification and the following claims, unless the context requires otherwise, the term "comprises" and variations thereof (such as comprises 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, unless otherwise indicated, the term "about" means ±20%.

[0648] It will be understood by those skilled in the art that numerous changes and modifications are obvious. All such changes and modifications obvious to those skilled in the art should be considered to fall within the spirit and scope of the foregoing invention.

Claims

1. A robotic block laying machine for constructing a block structure, the robotic block laying machine comprising: a) base; b) a boom extending from the base; c) a plurality of shuttle devices, wherein each of the shuttle devices is configured to: i) receiving blocks; and ii) traveling along the boom to transport the blocks along the boom; and d) a block laying robot disposed at the distal end of the boom, wherein the block laying robot is configured as follows: i) receiving the shuttle from the boom; and ii) positioning the shuttle device adjacent to a block laying location so that the shuttle device can release the block for laying.

2. The robotic block laying machine according to claim 1, wherein: The block laying robot comprises: a) Laying arms; and b) an end effector depending from the lay arm for manipulating the shuttle, wherein the end effector receives a loaded shuttle carrying blocks and the lay arm moves the end effector to position the shuttle adjacent the block lay location.

3. The robotic block laying machine according to claim 1 or claim 2, further comprising at least one transfer robot configured to pick up one of the blocks provided in the base and transfer the block to the shuttle device.

4. The robotic block laying machine according to any one of claims 1 to 3, further comprising a tower rotatably mounted to the base about a boom swivel axis, the tower supporting the boom and the boom being pivotally connected to the tower.

5. A robotic block laying machine according to any preceding claim, wherein the robotic block laying machine is mounted to a support frame which is in turn mounted to the chassis of a vehicle.

6. A robotic block laying machine according to any preceding claim, wherein: The boom includes a plurality of boom elements and rod elements, and at least one pivot joint is formed between the boom elements and the rod elements.

7. A robotic block laying machine according to any preceding claim, wherein: The shuttle is configured to transport the blocks through an interior of the boom.

8. A robotic block laying machine according to any preceding claim, wherein: The shuttle device travels along a track provided between the base and the block laying robot.

9. The robotic block laying machine according to claim 8, wherein: The track includes a sending track and a return track to accommodate a shuttle device going to the block laying robot and returning to the base.

10. The robotic block laying machine according to claim 9, wherein: The track includes a fixed track segment and a movable track segment.

11. The robotic block laying machine according to claim 10, wherein: The movable track segment comprises a track capable of translation or rotation.

12. A robotic block laying machine according to any preceding claim, wherein the shuttle is bi-directional, travelling forwards and backwards.

13. The robotic block laying machine according to any one of claims 3 to 12, wherein: The base is configured to receive one or more packages of building blocks, and the at least one transfer robot is configured to pick one of the building blocks from the packages of building blocks.

14. The robotic block laying machine according to claim 13, wherein: The blocks are packed in a single file in the base of the machine at designated packing stations.

15. The robotic block laying machine of claim 14, wherein: The blocks packages are fed into the machine onto a package conveyor module which is used to move the packages forward to an empty package station.

16. The robotic block laying machine of claim 15, wherein: Each of the packet conveyor modules comprises: a) base frame; and b) a drive assembly comprising a plurality of chains extending along the length of the base frame between a pair of shafts and spaced apart along the width of the base frame, wherein the chains are driven by a motor connected to one of the shafts.

17. A robotic block laying machine according to claim 15 or claim 16, wherein: The packages of blocks are provided on pallets, and empty pallets are removed from a pack conveyor module by a pallet ejection robot which picks up the empty pallet and moves it to a pallet storage location for removal from the robotic block laying machine.

18. The robotic block laying machine of claim 17, wherein: The tray ejection robot comprises: a) a carriage support slidably mounted to the frame for longitudinal travel thereof; and b) a carriage slidably mounted to the carriage support for traveling up and down the carriage support, the carriage comprising: i) a body arranged to travel along said carriage support; and ii) an engagement means slidably mounted to the carriage for transverse travel towards and away from the carriage support, wherein in operation the empty pallet is secured by the engagement means and picked up and moved to the pallet storage location.

19. The robotic block laying machine of claim 18, wherein: The engaging means comprises one of the following: a) a wedge-shaped clamp having jaws that engage a portion of the pallet; b) a vacuum gripper that engages the pallet by suction; and c) A clamp gripper having jaws that clamp around the pallet.

20. The robotic block laying machine of claim 17, wherein: The pallet ejection robot operates to lift the empty pallet above an adjacent block package and transport the empty pallet to the rear of the base where it is placed on pallet rests arranged between opposing side frames of the base.

21. The robotic block laying machine according to any one of claims 3 to 20, wherein: The at least one transfer robot comprises: a) a post support slidably mounted to the frame for longitudinal travel thereof; b) a beam having one end slidably mounted to the column support member so as to move up and down along the column support member; c) a carriage slidably mounted to the crossbar for transverse movement along the crossbar; and d) an arm slidably mounted to the carriage for up and down movement, wherein a distal end of the arm includes a gripping mechanism for picking up a block.

22. The robotic block laying machine according to any one of claims 4 to 21, further comprising a shuttle sequencing system configured to store shuttles in the base, the shuttle sequencing system comprising: a) a shuttle storage area comprising multiple layers of tracks on which the shuttles travel and are stored when not in use; b) means for moving the shuttle device to different levels of track in the storage area; as well as c) a shuttle translator configured to move the shuttle into and out of the shuttle storage area.

23. The robotic block laying machine of claim 22, wherein: The at least one transfer robot places building blocks into a shuttle disposed on a top track of the shuttle storage area.

24. The robotic block laying machine of claim 23, wherein: The top track is used by a departing shuttle loaded with blocks, and the middle and bottom tracks are used by a returning empty shuttle or a malfunctioning shuttle.

25. The robotic block laying machine according to any one of claims 22 to 24, wherein The shuttle device sorting system includes a shuttle device elevator configured to move the shuttle devices arranged thereon to different levels of tracks in the storage area.

26. The robotic block laying machine of claim 25, wherein: The shuttle translator is located adjacent the shuttle elevator.

27. A robotic block laying machine according to claim 25 or claim 26, wherein: The shuttle device sorting system includes a first and a second shuttle device elevator located at opposite ends of the track of the storage area, and the first and second shuttle device elevators are configured to move the shuttle devices arranged thereon to different levels of the track of the storage area.

28. The robotic block laying machine of claim 27, wherein: The first shuttle elevator travels between the bottom track and middle track of the shuttle storage area, and the second shuttle elevator travels between the top, middle, and bottom tracks.

29. The robotic block laying machine according to any one of claims 22 to 28, further comprising a turntable concentrically aligned with the boom slew ring at the bottom of the tower, the turntable rotatable about the tower and comprising a plurality of radially spaced turntable rotators, each of the turntable rotators being provided with two pairs of tracks configured to: a) receiving a loaded shuttle from the shuttle translator and driving the loaded shuttle to the tower track segment; and b) Receiving an empty shuttle from the tower track segment and driving the empty shuttle to the shuttle translator.

30. The robotic block laying machine of claim 29, wherein: Each of the turntable rotators includes first and second spaced-apart turntable rotator track segments, and each of the turntable rotators is configured to rotate from a first position in which the rotator track is aligned with the shuttle translator track segment to a second position in which the rotator track is aligned with the tower track segment.

31. The robotic block laying machine of claim 30, wherein: The turntable has three turntable rotators for storing shuttles with the required blocks in the block laying sequence.

32. The robotic block laying machine according to any one of claims 29 to 31, wherein In use, the shuttle translator is moved laterally from the shuttle storage area to the turntable, while the turntable is rotated to align one of the turntable rotators with the translator to receive the shuttle thereon, the turntable is then rotated to position the loaded turntable rotator adjacent to the tower track segment, and the loaded turntable rotator is then rotated to align the turntable rotator track segment with the tower track segment to allow the shuttle to travel between the turntable and the tower.

33. The robotic block laying machine according to any one of claims 29 to 32, wherein: The turntable is powered by electrical slip rings which allow for continuous rotation.

34. The robotic block laying machine according to any one of claims 29 to 33, wherein During transfer of the shuttle between the turntable rotator and the tower, the rotation of the turntable is slaved to track the swinging motion of the boom.

35. The robotic block laying machine according to any one of claims 29 to 34, wherein The tower includes a boom pivot about which a proximal end of the boom pivots, and a tower rotator pivotally mounted to the tower for coaxial pivoting with the boom pivot, the tower rotator for transferring a shuttle between the tower and the boom.

36. The robotic block laying machine of claim 35, wherein: The tower rotator includes a body having tower rotator track segments configured to receive a loaded shuttle device heading to the block laying robot or an empty shuttle device returning to the shuttle device storage area, and the tower rotator is configured to pivot between a first position and a second position, in which the tower rotator track is aligned with the tower track segments to align with the tower transfer shuttle device, and in which the tower rotator track segments are aligned with the boom track segments to align with the boom transfer shuttle device.

37. The robotic block laying machine of claim 36, wherein: During the transition shuttle between the tower rotator and boom, the pivoting motion of the tower rotator is slaved to the lifting angle of the boom.

38. The robotic block laying machine according to any one of claims 6 to 37, wherein The boom includes two pairs of telescoping boom members and rod members with at least one pivot joint therebetween, and each member includes a track segment extending substantially along the length of each member, the track segments being configured to allow a shuttle to travel along the boom.

39. The robotic block laying machine of claim 38, wherein: Each boom or rod track segment includes two layers of inner track including a first track on which a loaded shuttle travels to a block-laying robot of the robotic block laying machine and a lower track on which an empty shuttle returns to a base of the block-laying robot.

40. The robotic block laying machine according to any one of claims 2 to 39, wherein The end effector of the block laying robot includes an upper track and a lower track, and is configured to transfer the shuttle device from the lower track to the upper track after the blocks are laid.

41. The robotic block laying machine of claim 40, wherein: A loaded shuttle travels to the lower track of the end effector, and an empty shuttle travels in the opposite direction from the upper track of the end effector to exchange shuttles between the boom and the end effector.

42. The robotic block laying machine of claim 41, wherein: The shuttles are exchanged simultaneously.

43. A robotic block laying machine according to claim 41 or claim 42, wherein: The shuttle is exchanged between the boom and the end effector by a shuttle rotator disposed between the boom and the lay arm, which rotates the shuttle 180 degrees.

44. The robotic block laying machine of claim 43, wherein: The block-laying robot is part of a laying head comprising a support tower pivotally connected to a distal end of the boom, and the block-laying robot is suspended from the support tower.

45. The robotic block laying machine of claim 44, wherein: The support tower of the laying head includes a U-shaped body having a pair of arms by which the U-shaped body is pivotally mounted for controlled rotation relative to the distal end of the boom, and the shuttle rotator is mounted to the support tower.

46. ​​The robotic block laying machine of claim 45, wherein: The shuttle rotator includes an upper track and a lower track, and the loaded shuttle running along the upper track of the boom runs to the upper track of the shuttle rotator, and the shuttle rotator rotates 180 degrees to flip the loaded shuttle, thereby running it to the lower track of the end effector with the blocks in a downward laying posture.

47. A robotic block laying machine according to claim 45 or claim 46, wherein: The block laying robot is a spherical geometry robot, the laying arm extends linearly in the radial direction and is rotationally controlled in roll and pitch directions via a support tower joint, while the end effector is controllable in roll, pitch and yaw directions via a wrist joint.

48. The robotic block laying machine of any preceding claim, further comprising an adhesive application system configured to be supported adjacent the block laying robot, comprising: a) at least one adhesive tank; b) a nozzle outlet configured to spray adhesive onto a lower surface of the block; c) a supply line extending from said at least one adhesive tank to said nozzle outlet; as well as d) A motor drives a gear pump that pumps the adhesive through the supply line.

49. The robotic block laying machine of claim 48, wherein: As the shuttle travels past the nozzle outlet, adhesive is sprayed onto the blocks.

50. The robotic block laying machine according to any one of claims 5 to 49, further comprising an outrigger system for stabilising the vehicle during operation, the outrigger system depending from the support frame and comprising front folding legs arranged on opposite sides of the vehicle, the folding legs being pivotally connected to foot pads and, in use, the legs being deployed at an angle to the ground.

51. The robotic block laying machine of claim 50, wherein: The front folding legs are inclined forward.

52. A robotic block laying machine according to claim 50 or claim 51, wherein: The outer ends of the front folding legs are lower.

53. The robotic block laying machine according to any one of claims 50 to 52, wherein In use, the front folding legs are deployed on the building side of the vehicle.

54. The robotic block laying machine according to any one of claims 50 to 53, wherein The outrigger system also includes front jacks, each having an upright plunger, mounted adjacent the folding legs on opposite sides of the vehicle for use on the road side of the vehicle.

55. The robotic block laying machine according to any one of claims 50 to 54, wherein The outrigger system also includes rear extension legs on opposite sides of the vehicle, each of the rear extension legs having an upright plunger deployable in any extended position of the leg.

56. The robotic block laying machine of any one of claims 5 to 55, further comprising an onboard generator capable of operating in a generator mode or a motor mode, the generator being driven by the vehicle's diesel engine via a power take-off (PTO) and a drive shaft.

57. The robotic block laying machine of claim 56, wherein the machine's electrical system is powered by one of the generator or shore power.

58. The robotic block laying machine of claim 56 or 57, wherein: The robotic block laying machine includes a hydraulic system including a hydraulic pump driven by the vehicle's diesel engine or the generator in motor mode.

59. The robotic block laying machine according to any one of claims 5 to 58, wherein The vehicle includes one of the following: a) Rigid body trucks; b) a semitrailer for connection to a tractor; and c) Trailer.

60. A robotic block laying machine according to any preceding claim, wherein: A block is one of the following: a) Bricks or blocks used for building walls; b) tiles used in the construction of roofs; and c) Paving blocks used in the construction of external floors.

61. A vehicle comprising a robotic block laying machine for constructing a block structure, the vehicle comprising: a) Vehicle chassis; b) a support frame mounted to the chassis; as well as c) a robotic block laying machine mounted from the support frame, the robotic block laying machine comprising: i) base; ii) a boom extending from the base; and iii) a plurality of shuttle devices, wherein each of said shuttle devices is configured to: (1) receiving blocks; and (2) traveling along the boom to transport the blocks along the boom; and iv) a block laying robot disposed at the distal end of the boom, wherein the block laying robot is configured as follows: (1) receiving the shuttle device from the boom; and (2) Positioning the shuttle device near the block laying position so that the shuttle device can release the block and thereby lay the block.

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