Additive and subtractive integrated intelligent construction system and method for special-shaped structure

Abstract

The invention provides an additive and subtractive integrated intelligent construction system and method for a special-shaped structure, and the system comprises a hybrid layered construction (HLC) software system which is used for generating and converting a control instruction which can be executed by a robot system based on an input design model; the hybrid intelligent construction HIC controller is used for generating and coordinating corresponding control instructions of the additive tasks and the subtractive tasks on the basis of the control instructions from the hybrid hierarchical construction HLC software system; and the hybrid intelligent construction hardware system is used for executing the control instructions of the material increase task and the material decrease task sent by the hybrid intelligent construction HIC controller. High-precision and efficient construction of a large complex special-shaped structure is achieved, and material waste can be reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of special-shaped structure additive and subtractive integrated intelligent construction system and method. BACKGROUND

[0002] With the development of building or structure design diversification, the traditional construction method is difficult to adapt to the design requirements of complex, non-standard geometry. Additive manufacturing (3D printing) technology provides the possibility for the automation, flexible construction of complex, lightweight, topologically optimized structure, but it has problems such as rough surface, low dimensional accuracy when constructing large building structures (usually ≥1m), and faces the challenges of efficiency and cost; subtractive manufacturing (CNC machining) technology can realize the construction of large structure with high precision, and the reinforced structure surface quality is high, but it has serious material waste, and it is difficult to build complex internal cavity structure. SUMMARY

[0003] The purpose of the present application is to provide a kind of special-shaped structure additive and subtractive integrated intelligent construction system and method.

[0004] To solve the above problems, the present application provides a kind of special-shaped structure additive and subtractive integrated intelligent construction system, comprising:

[0005] Hybrid Layered Construction HLC Software System 100, for generating control instructions converted into robot system executable based on input design model, and sending to Hybrid Intelligent Construction HIC Controller 20);

[0006] Hybrid Intelligent Construction HIC Controller 200, based on control instructions from Hybrid Layered Construction HLC Software System 100, generates and coordinates control instructions for corresponding additive and subtractive tasks, and sends to Hybrid Intelligent Construction Hardware System 300 for execution;

[0007] Hybrid Intelligent Construction Hardware System 300, executes the control instructions of additive and subtractive tasks issued by Hybrid Intelligent Construction HIC Controller 200.

[0008] Further, in the above system, the Hybrid Layered Construction HLC Software System 100 comprises:

[0009] Model Checking and Repairing Module 110, for integrity checking and repairing defects in the input design model to obtain the repaired design model;

[0010] Additive and Subtractive Feature Recognition Module 120, for analyzing the repaired design model to identify the processing features corresponding to the additive or subtractive process;

[0011] a virtual building and evaluation module 130 configured to simulate the entire manufacturing process based on the machining features of the additive or subtractive process and to make optimization adjustments according to the simulation results to obtain a virtual building result;

[0012] a path planning and parameter optimization module 140 configured to formulate optimized manufacturing paths and building parameter settings based on the virtual building result;

[0013] a code generation module 150 configured to convert the optimized manufacturing paths and building parameters into control instructions executable by the robotic system.

[0014] Further, in the above system, the hybrid intelligent building HIC controller 200 comprises:

[0015] a motion control module 210 configured to generate first control instructions for controlling the actions of the robotic system based on the control instructions from the code generation module 150, to realize seamless conversion from design to production;

[0016] a 3D printing process control module 220 configured to generate second control instructions for managing and controlling the 3D printing process based on the control instructions from the code generation module 150, to ensure printing precision and quality.

[0017] a subtractive-additive switching control module 230 configured to generate third control instructions for coordinating the conversion between additive and subtractive processes based on the control instructions from the code generation module 150;

[0018] a subtractive building control module 240 configured to generate fourth control instructions for executing subtractive machining tasks based on the control instructions from the code generation module 150;

[0019] a metrology-aware control module 250 configured to monitor key indicators during the entire building process by sending fifth control instructions to the metrology-aware system 350 based on the control instructions from the code generation module 150, to coordinate the control instruction adjustments of the motion control module 210, the 3D printing process control module 220, the subtractive-additive switching control module 230, and the subtractive building control module 240, to ensure compliance with predetermined standards.

[0020] Further, in the above system, the hybrid intelligent building hardware system 300 comprises:

[0021] a robotic system 310 configured to perform actual physical operations according to the first control instructions issued by the motion control module 210;

[0022] a 3D printing system 320 configured to perform material printing work during the additive manufacturing process based on the second control instructions issued by the 3D printing process control module 220;

[0023] an additive-subtractive switching system 330 for switching between the additive mode of the 3D printing robot system and the subtractive mode of the subtractive manufacturing system according to the third control instruction issued by the additive-subtractive switching control module 230;

[0024] a subtractive manufacturing system 340 for implementing a subtractive manufacturing process according to the fourth control instruction issued by the subtractive manufacturing control module 240;

[0025] a metrology perception system 350 for collecting data in real time, monitoring printing parameters, material parameters, geometric parameters and environmental parameters of the manufacturing process, and sending them to the metrology perception control module 250 to provide feedback for the metrology perception control module 250 to support closed-loop control.

[0026] According to another aspect of the present application, there is also provided a heterogeneous structure additive-subtractive integrated intelligent manufacturing method, characterized in that the method uses the heterogeneous structure additive-subtractive integrated intelligent manufacturing system of any one of the above aspects, and the method comprises:

[0027] virtual manufacturing of the heterogeneous structure by the hybrid layer construction HLC software system 100 to obtain control instructions executable by the robot system;

[0028] the hybrid intelligent construction HIC controller 200 performs additive-subtractive integrated manufacturing of the heterogeneous structure based on the control instructions.

[0029] Further, in the above method, the virtual manufacturing of the heterogeneous structure by the hybrid layer construction HLC software system 100 to obtain control instructions executable by the robot system comprises:

[0030] the three-dimensional digital model of the complex heterogeneous structure is imported into the hybrid layer construction HLC software system 100, the three-dimensional digital model is automatically checked for integrity, tolerance and geometric requirements by the model checking and repairing module 110, and possible defects are repaired to form a repaired three-dimensional digital model meeting the additive-subtractive requirements;

[0031] the repaired three-dimensional digital model of the heterogeneous structure is analyzed for features by the additive-subtractive feature recognition module 120, and the feature areas suitable for additive manufacturing and the feature areas suitable for subtractive manufacturing are identified according to the geometric specifications and the quality state of the machining features, and the planning and feature sorting of the feature areas suitable for additive manufacturing and the feature areas suitable for subtractive manufacturing are set;

[0032] the virtual manufacturing and evaluation module 130 simulates the entire manufacturing process based on the planning and feature sorting of the feature areas suitable for additive manufacturing and the feature areas suitable for subtractive manufacturing, combines with the preset process library parameters, predicts the additive interlayer stress concentration points, simulates the subtractive cutting trajectory, and optimizes and adjusts according to the results to obtain the virtual manufacturing results;

[0033] Based on the result of virtual construction, an optimized manufacturing path and construction parameter are formulated by the path planning and parameter optimization module 140;

[0034] The optimized manufacturing path and construction parameter are converted into control instructions executable by the robot system by the code generation module 150.

[0035] Further, in the above method, the manufacturing path comprises a printing path and a subtractive path.

[0036] Further, in the above method, the construction parameter comprises:

[0037] Printing parameter P i , including printing speed, layer height h p and printing layer time interval;

[0038] Subtractive machining parameter S j , including subtractive speed and subtractive depth hs;

[0039] Robot system parameter R k , including target coordinates, target sequence and robot motion speed.

[0040] Further, in the above method, the optimized manufacturing path and construction parameter satisfy equations (1)-(4), and for the case of considering material utilization, equation (5) is also satisfied:

[0041] M(P i ,S j ,R k )=min∑(M Pm +M Sn ) (1)

[0042] t(P i ,S j ,R k )=min∑(t Pm +t Sn ) (2)

[0043] E(P i ,S j ,R k )=min∑(E Pm +E Sn ) (3)

[0044] C(P i ,S j ,R k )=min∑(C Pm +C Sn ) (4)

[0045]

[0046] wherein P i is a printing parameter, S j is a subtractive machining parameter, R k是 is a robotic system parameter;

[0047] M(P i ,S j ,R k ), t(P i ,S j ,R k ), E(P i ,S j ,R k ) and C(P i ,S j ,R k ) are the minimum material consumption, minimum build time, minimum energy consumption and minimum cost, respectively;

[0048] η(P i ,S j ,R k ) is the maximum material utilization;

[0049] M Pm , t Pm , E Pm and C Pm are the material mass, printing time, printing energy consumption and printing cost required for printing the mth feature region of the additive build, respectively;

[0050] M Sn , t Sn , E Sn and C Sn are the material mass, subtractive machining time, subtractive machining energy consumption and subtractive machining cost consumed by the nth feature region of the subtractive build, respectively;

[0051] V(P i ,S j ,R k ) is the net volume of the final built structure;

[0052] ρ(P i ,S j ,R k ) is the material density.

[0053] Further, in the above method, the hybrid intelligent construction (HIC) controller 200 performs the hybrid additive-subtractive construction of the irregular structure based on the control instructions, comprising:

[0054] The additive and subtractive material switching control module 230 of the hybrid intelligent construction controller 200 sends a third control instruction to the additive and subtractive material switching system 330 in the hybrid intelligent construction hardware system 300 to automatically switch to the additive mode;

[0055] The first control instruction is sent to the robot system 310 by the motion control module 210, and the second control instruction is sent to the 3D printing system 320 by the 3D printing process control module 220 to print the special-shaped structure ACS1 according to the pre-planned path and printing parameters. The fifth control instruction is sent to the metrology perception system 350 by the metrology perception control module 250 to monitor the quality of printing. The deviation of the geometric parameters from the model is monitored every NP layer, and if the deviation meets the set requirements, the printing is continued. If the deviation does not meet the requirements, the system automatically adjusts the printing parameters of the subsequent layers for compensation.

[0056] (3) When the special-shaped structure ACS1 is completed, the third control instruction is sent to the additive and subtractive material switching system 330 by the additive and subtractive material switching control module 230 to automatically switch to the subtractive mode.

[0057] (4) The first control instruction is sent to the robot system 310 by the motion control module 210, and the fourth control instruction is sent to the subtractive construction system 340 by the subtractive construction control module 240 to process the subtractive part SCS1 of the special-shaped structure ACS1 according to the pre-planned path and subtractive processing parameters. The fifth control instruction is sent to the metrology perception system 350 by the metrology perception control module 250 to monitor the quality of subtractive processing. The deviation of the geometric parameters from the model is monitored every NS layer, and if the deviation meets the set requirements, the subtractive processing is continued. If the deviation does not meet the requirements, the system automatically adjusts the subtractive processing parameters of the subsequent layers for compensation.

[0058] (5) The steps of printing the special-shaped structure ACSm and subtractive processing the SCSn are repeated from (1) to (4) to finally complete the construction of the special-shaped structure 400.

[0059] (6) The additive and subtractive material process data, process parameters, error compensation records and detection reports are obtained by the metrology perception control module 250 for the delivery of the printed product for use.

[0060] Compared with the prior art, the present application relates to the technical field of intelligent construction, and is used for automatically, efficiently and accurately constructing complex special-shaped structures. The present application solves the technical problems caused by the separation of additive manufacturing and subtractive manufacturing in existing automatic construction technology, and solves the problems of poor surface quality, low construction efficiency, low material utilization rate and limited construction capacity of complex structures caused by using single additive manufacturing or subtractive manufacturing method, realizes high-precision and efficient construction of large and complex special-shaped structures, and reduces material waste.

[0061] The application solves the problem of integrated additive and subtractive intelligent construction of large special-shaped structures, breaks through the limitations of traditional construction methods in dealing with complex geometric shapes, improves the construction precision, efficiency and material utilization rate of special-shaped structures, and the construction precision can reach 1mm. Taking the special-shaped formwork of cast-in-place concrete construction as an example, compared with the traditional wooden formwork, the processing time of the integrated additive and subtractive intelligent construction plastic-based formwork is shortened by 60%, and the material waste is reduced by more than 80%; compared with the steel formwork, the processing time of the integrated additive and subtractive intelligent construction plastic-based formwork is shortened by 30%, and the cost is reduced by more than 50%. Compared with the traditional construction method, the construction method can realize the closed-loop control of "perception-decision-execution", support unmanned construction, realize the integrated process construction from design to building product, simplify the construction process, and has wide adaptability, and is suitable for the construction of concrete, plastic-based materials and composite materials and other materials. BRIEF DESCRIPTION OF DRAWINGS

[0062] Figure 1 is a flowchart of the integrated additive and subtractive intelligent construction system of the special-shaped structure of an embodiment of the application;

[0063] Figure 2 is a principle diagram of the integrated additive and subtractive switching system 330 of an embodiment of the application;

[0064] Figure 3 is a schematic diagram of the feature area and sorting of the integrated additive and subtractive intelligent construction of a special-shaped structure of an embodiment of the application;

[0065] Figure 4 is a flowchart of the integrated additive and subtractive intelligent construction of a special-shaped structure of an embodiment of the application. DETAILED DESCRIPTION

[0066] The application will be further described in detail below with reference to the drawings.

[0067] In a typical configuration of the present application, the terminal, the device of the service network and the trusted party each include one or more processors (CPU), input / output interfaces, network interfaces and memories.

[0068] The memory can include a non-permanent memory in a computer readable medium, random access memory (RAM) and / or non-volatile memory such as read-only memory (ROM) or flash memory (flash RAM). The memory is an example of a computer readable medium.

[0069] Computer-readable media includes permanent and non-permanent, removable and non-removable media implemented in any method or technology for information storage. Information can be computer-readable instructions, data structures, program modules or other data. Examples of computer storage media include, but are not limited to, phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, compact disc read-only memory (CD-ROM), digital versatile disc (DVD) or other optical storage, magnetic cassette, magnetic tape disk storage or other magnetic storage devices, or any other non-transmission medium that can be used to store information accessible to a computing device. According to the definition herein, computer-readable media does not include transitory media, such as modulated data signals and carriers.

[0070] As shown in Figure 1 The present application provides a special-shaped structure additive and subtractive integrated intelligent construction system, comprising:

[0071] The hybrid layered construction HLC software system 100 is used to generate control instructions converted into executable instructions of the robot system based on the input design model, and send the control instructions to the hybrid intelligent construction HIC controller 200;

[0072] The hybrid intelligent construction HIC controller 200 generates and coordinates control instructions of corresponding additive tasks and subtractive tasks based on the control instructions from the hybrid layered construction HLC software system 100, and sends the control instructions to the hybrid intelligent construction hardware system 300 for execution;

[0073] The hybrid intelligent construction hardware system 300 executes the control instructions of the additive tasks and subtractive tasks issued by the hybrid intelligent construction HIC controller 200.

[0074] In an embodiment of the special-shaped structure additive and subtractive integrated intelligent construction system of the present application, the hybrid layered construction HLC software system 100 comprises:

[0075] The model checking and repairing module 110 is used to check the integrity of the input design model and repair the existing defects to obtain a repaired design model;

[0076] The additive and subtractive feature recognition module 120 is used to analyze the repaired design model and identify the processing features corresponding to the additive process or the subtractive process;

[0077] a virtual construction and evaluation module 130 for simulating the entire manufacturing process based on the machining features of the additive or subtractive process and making optimization adjustments according to the simulation results to obtain a virtual construction result;

[0078] a path planning and parameter optimization module 140 for formulating optimized manufacturing paths and construction parameter settings based on the virtual construction result;

[0079] Here, the manufacturing path includes a printing path and a subtractive path.

[0080] a code generation module 150 for converting the optimized manufacturing path and construction parameters into control instructions executable by the robot system for subsequent stages.

[0081] In an embodiment of the heterogeneous structure additive and subtractive integrated intelligent construction system of the present application, the hybrid intelligent construction HIC controller 200 includes:

[0082] a motion control module 210 for generating first control instructions for controlling the actions of the robot system based on the control instructions from the code generation module 150, realizing seamless conversion from design to production;

[0083] a 3D printing process control module 220 for generating second control instructions for managing and controlling the 3D printing process based on the control instructions from the code generation module 150, ensuring printing precision and quality.

[0084] a subtractive-additive switching control module 230 for generating third control instructions for coordinating the transition between additive and subtractive processes based on the control instructions from the code generation module 150, ensuring smooth transition;

[0085] a subtractive construction control module 240 for generating fourth control instructions for executing subtractive machining tasks such as cutting, drilling, etc. based on the control instructions from the code generation module 150.

[0086] a metrology perception control module 250 for monitoring key indicators during the entire construction process by sending fifth control instructions to the metrology perception system 350 based on the control instructions from the code generation module 150, coordinating the control instruction adjustments of the motion control module 210, 3D printing process control module 220, subtractive-additive switching control module 230 and subtractive construction control module 240 to ensure compliance with predetermined standards.

[0087] In an embodiment of the heterogeneous structure additive and subtractive integrated intelligent construction system of the present application, the hybrid intelligent construction hardware system (300) includes:

[0088] The robot system 310 is used to make the robot system perform actual physical operations such as movement and rotation according to the first control instruction issued by the motion control module 210;

[0089] Specifically, the 3D printing robot system can be a ≥4-axis system, and the subtractive manufacturing system can be a ≥5-axis system.

[0090] The 3D printing system 320 is used to perform material printing work in the additive manufacturing process based on the second control instruction issued by the 3D printing process control module 220.

[0091] Preferably, the 3D printing system 320 includes but is not limited to a concrete 3D printing head, a plastic-based 3D printing head, and a material supply system.

[0092] The additive-subtractive switching system 330 is used to switch between the additive mode of the 3D printing robot system and the subtractive mode of the subtractive manufacturing system according to the third control instruction issued by the additive-subtractive switching control module 230.

[0093] The subtractive manufacturing system 340 is used to implement subtractive manufacturing processes such as cutting and drilling according to the fourth control instruction issued by the subtractive manufacturing control module 240.

[0094] The metrology perception system 350 is used to collect data in real time, monitor printing parameters, material parameters, geometric parameters, and environmental parameters of the construction process, and send them to the metrology perception control module 250 to provide feedback for the metrology perception control module 250 and support closed-loop control.

[0095] Preferably, the printing parameters include printing speed, layer height h p , and printing layer time interval.

[0096] The material parameters include temperature and strength.

[0097] The geometric parameters include layer height, layer width, and geometric scale. The geometric parameters are measured by a laser and visual combined sensor with a detection accuracy of within 0.1 mm.

[0098] The environmental parameters include environmental temperature and humidity.

[0099] Specifically, as Figure 1 shown, the special-shaped structure additive-subtractive integrated intelligent construction system of the present application includes:

[0100] A hybrid layered construction (HLC) software system 100, a hybrid intelligent construction (HIC) controller 200, and a hybrid intelligent construction hardware system 300.

[0101] The hybrid layered construction HLC software system 100 is composed of a model checking and repairing module 110, an additive and subtractive feature identification module 120, a virtual construction and evaluation module 130, a path planning and parameter optimization module 140, and a code generation module 150.

[0102] The hybrid intelligent construction HIC controller 200 is composed of a motion control module 210, a 3D printing process control module 220, an additive and subtractive switching control module 230, a subtractive construction control module 240, and a metrology sensing control module 250.

[0103] The hybrid intelligent construction hardware system 300 is composed of a robot system 310, a 3D printing system 320, an additive and subtractive switching system 330, a subtractive construction system 340, and a metrology sensing system 350.

[0104] As shown in Figure 1 , Figure 2 , Figure 3 and Figure 4 , the present application also provides a hybrid additive and subtractive intelligent construction method for special-shaped structures, which comprises the following steps:

[0105] Step 1: Virtual construction of a special-shaped structure is performed by using a hybrid layered construction HLC software system 100 to obtain control instructions executable by a robot system:

[0106] (1) A three-dimensional digital model of a complex special-shaped structure is imported into the hybrid layered construction HLC software system 100, and the model checking and repairing module 110 is used to automatically check the integrity, tolerances, and geometric requirements of the three-dimensional digital model, and repair possible defects to form a repaired three-dimensional digital model meeting the requirements of additive and subtractive construction;

[0107] (2) The repaired three-dimensional digital model of the special-shaped structure is analyzed for features by using the additive and subtractive feature identification module 120, and according to the geometric specifications and the quality state of the machining features, feature areas suitable for additive construction (ACS) and feature areas suitable for subtractive construction (SCS) are identified, and the planning and feature sorting of the feature areas suitable for additive construction (ACS) and the feature areas suitable for subtractive construction (SCS) are set, as shown in Figure 3 .

[0108] Here, the geometric specifications include dimensional tolerances and surface roughness;

[0109] (3) Based on the planning and feature sorting of the feature areas suitable for additive construction (ACS) and the feature areas suitable for subtractive construction (SCS) identified, the virtual construction and evaluation module 130 is used to simulate the entire manufacturing process in combination with preset process library parameters; to predict stress concentration points between additive layers; to simulate subtractive cutting trajectories, and to optimize and adjust the results to obtain virtual construction results;

[0110] (4) Based on the result of virtual construction, an optimized manufacturing path (printing path and subtractive path) and construction parameters are formulated by the path planning and parameter optimization module 140.

[0111] The manufacturing path includes a printing path and a subtractive path.

[0112] The construction parameters include:

[0113] Printing parameters P i include printing speed, layer height h p and printing layer time interval.

[0114] Subtractive machining parameters S j include subtractive speed and subtractive depth hs.

[0115] Robot system parameters R k include target coordinates, target order, and robot motion speed.

[0116] Preferably, the optimized manufacturing path and construction parameters satisfy equations (1)-(4), and for the case of considering material utilization, equation (5) is also satisfied:

[0117] M(P i ,S j ,R k )=min∑(M Pm +M Sn ) (1)

[0118] t(P i ,S j ,R k )=min∑(t Pm +t Sn ) (2)

[0119] E(P i ,S j ,R k )=min∑(E Pm +E Sn ) (3)

[0120] C(P i ,S j ,R k )=min∑(C Pm +C Sn ) (4)

[0121]

[0122] In the equations, P i is the printing parameter, S j is the subtractive machining parameter, and Rk是 robot system parameters;

[0123] M(P i ,S j ,R k ), t(P i ,S j ,R k ), E(P i ,S j ,R k ) and C(P i ,S j ,R k ) are the minimum material consumption, minimum construction time, minimum energy consumption and minimum cost, respectively;

[0124] η(P i ,S j ,R k ) is the maximum material utilization rate;

[0125] M Pm , t Pm , E Pm and C Pm are the material mass, printing time, printing energy consumption and printing cost required for printing the mth feature region of additive construction, respectively;

[0126] M Sn , t Sn , E Sn and C Sn are the material mass, subtractive processing time, subtractive processing energy consumption and subtractive processing cost consumed by the nth feature region of subtractive construction, respectively;

[0127] V(P i ,S j ,R k ) is the net volume of the final constructed structure;

[0128] ρ(P i ,S j ,R k ) is the material density, which is usually a fixed value, and for cases where the construction parameters have a large impact, it needs to be determined through experiments with different construction parameters.

[0129] (5) The optimized manufacturing path and construction parameters are converted into control instructions executable by the robot system by the code generation module 150, and the control instructions are not limited to G code.

[0130] Step two, the hybrid intelligent construction (HIC) controller 200 performs integrated additive and subtractive construction of the special-shaped structure based on the control instructions:

[0131] (1) The HIC controller 200 mixes the additive and subtractive material switching control module 230 to send the third control instruction to the additive and subtractive material switching system 330 in the hybrid intelligent construction hardware system 300, and automatically switches to the additive mode;

[0132] (2) The first control instruction is sent to the robot system 310 through the motion control module 210, and the second control instruction is sent to the 3D printing system 320 through the 3D printing process control module 220, and the special-shaped structure ACS1 is printed according to the pre-planned path and printing parameters. The fifth control instruction is sent to the metrology perception system 350 by the metrology perception control module 250 during the printing process to monitor the quality of the printing. The deviation of the geometric parameters from the model is monitored every NP layer (NP≤3), and if the deviation meets the set requirements, the printing continues. If the deviation does not meet the requirements, the system automatically adjusts the printing parameters of the subsequent layers for compensation (usually ±5%).

[0133] (3) When the special-shaped structure ACS1 is completed, the third control instruction is sent to the additive and subtractive material switching system 330 through the additive and subtractive material switching control module 230, and the subtractive mode is automatically switched.

[0134] (4) The first control instruction is sent to the robot system 310 through the motion control module 210, and the fourth control instruction is sent to the subtractive construction system 340 through the subtractive construction control module 240, and the subtractive part SCS1 of the special-shaped structure ACS1 is processed according to the pre-planned path and subtractive processing parameters. The fifth control instruction is sent to the metrology perception system 350 by the metrology perception control module 250 during the printing process to monitor the quality of the subtractive material. The deviation of the geometric parameters from the model is monitored every NS layer (NS≤1), and if the deviation meets the set requirements, the subtractive processing continues. If the deviation does not meet the requirements, the system automatically adjusts the subtractive processing parameters of the subsequent layers for compensation (usually ±2%).

[0135] (5) Repeat steps (1) to (4) to print the special-shaped structure ACSm and process the subtractive material SCSn, and finally complete the construction of the special-shaped structure 400.

[0136] (6) The additive and subtractive material process data, process parameters, error compensation records and test reports are obtained through the metrology perception control module 250 for the delivery of the printed product for use.

[0137] In summary, the present application relates to the technical field of intelligent construction, and is used for automatically, efficiently and accurately constructing a complex special-shaped structure. The present application aims to provide a special-shaped structure additive and subtractive integrated intelligent construction system and method, solves the technical problem of process fragmentation caused by the separation of additive manufacturing and subtractive manufacturing in the existing automatic construction technology, and solves the problems of poor surface quality of structures constructed by using a single additive manufacturing or subtractive manufacturing method, low construction efficiency, low material utilization rate and limited construction capacity of complex structures, realizes high-precision and efficient construction of large complex special-shaped structures, and can reduce material waste.

[0138] The present application solves the problem of additive and subtractive integrated intelligent construction of large special-shaped structures, breaks through the limitations of traditional construction methods in processing complex geometrical shapes, improves the construction precision, efficiency and material utilization rate of special-shaped structures, and the construction precision can reach 1mm. Taking a special-shaped formwork for cast-in-place concrete construction as an example, the plastic-based formwork of additive and subtractive integrated intelligent construction has a processing time reduced by 60% and a material waste reduced by more than 80% compared with a traditional wooden formwork; and has a processing time reduced by 30% and a cost reduced by more than 50% compared with a steel formwork. Compared with the traditional construction method, the present construction method can realize closed-loop control of "perception-decision-execution", support unmanned construction, realize integrated process construction from design to building product, simplify the construction process, and has wide adaptability and is suitable for construction of various materials such as concrete, plastic-based materials and composite materials.

[0139] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application also intends to include these modifications and variations.

[0140] It should be noted that the present application can be implemented in software and / or a combination of software and hardware, for example, can be implemented by using an application specific integrated circuit (ASIC), a general purpose computer or any other similar hardware device. In one embodiment, the software program of the present application can be executed by a processor to implement the steps or functions described above. Similarly, the software program of the present application (including related data structures) can be stored in a computer readable recording medium, for example, a RAM memory, a magnetic or optical drive or a soft disk and the like. In addition, some steps or functions of the present application can be implemented by using hardware, for example, as a circuit cooperating with the processor to execute the respective steps or functions.

[0141] In addition, part of the present application can be applied as a computer program product, for example, computer program instructions, when executed by a computer, through the operation of the computer, the method and / or technical solutions according to the present application can be invoked or provided. The program instructions invoking the method of the present application can be stored in a fixed or removable recording medium, and / or transmitted through a data stream in a broadcast or other signal bearing medium, and / or stored in the working memory of the computer device running according to the program instructions. Here, according to an embodiment of the present application includes a device comprising a memory for storing computer program instructions and a processor for executing program instructions, wherein when the computer program instructions are executed by the processor, the device is triggered to run the method and / or technical solutions based on the foregoing according to the plurality of embodiments of the present application.

[0142] It is obvious to a person skilled in the art that the present application is not limited to the details of the above exemplary embodiments, but can be implemented in other concrete forms without departing from the spirit or essential characteristics of the present application. Therefore, the embodiments should be considered in all aspects as exemplary and non-limiting, and the scope of the present application is defined by the appended claims rather than the above description, and therefore all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present application. Any reference signs in the claims should not be considered as limiting the claims involved. In addition, it is obvious that the word "comprising" does not exclude other units or steps, and the singular does not exclude the plural. The plurality of units or devices stated in the device claim can also be implemented by one unit or device through software or hardware. The words first, second, etc. are used to indicate names, not any specific order.

Claims

1. An intelligent construction system integrating additive and subtractive building materials for irregularly shaped structures, characterized in that, include: Hybrid Layered Construction (HLC) software system (100) is used to generate control instructions that can be executed by the robot system based on the input design model and send them to the Hybrid Intelligent Construction (HIC) controller (200); The Hybrid Intelligent Construction (HIC) controller (200) generates and coordinates control instructions for corresponding additive and subtractive construction tasks based on control instructions from the Hybrid Layered Construction (HLC) software system (100), and sends them to the Hybrid Intelligent Construction hardware system (300) for execution. The hybrid intelligent construction hardware system (300) executes the control commands for additive and subtractive construction tasks issued by the hybrid intelligent construction HIC controller (200).

2. The intelligent construction system for irregularly shaped structures integrating additive and subtractive building materials as described in claim 1, characterized in that, The hybrid layered construction HLC software system (100) includes: The model inspection and repair module (110) is used to perform integrity checks on the input design model and repair existing defects to obtain the repaired design model; The additive or subtractive manufacturing feature recognition module (120) is used to analyze the repaired design model and identify the corresponding additive or subtractive manufacturing process features. The virtual construction and evaluation module (130) is used to simulate the entire manufacturing process based on the processing characteristics of additive or subtractive manufacturing processes, and to optimize and adjust the process based on the simulation results to obtain virtual construction results. The path planning and parameter optimization module (140) is used to formulate an optimized manufacturing path and construction parameter settings based on the virtual construction results; The code generation module (150) is used to convert the optimized manufacturing path and construction parameters into control instructions that can be executed by the robot system.

3. The intelligent construction system for irregularly shaped structures integrating additive and subtractive building materials as described in claim 1, characterized in that, The Hybrid Intelligent Construction (HIC) controller (200) includes: The motion control module (210) is used to generate first control instructions for controlling the actions of the robot system based on control instructions from the code generation module (150), thereby achieving a seamless transition from design to production; The 3D printing process control module (220) is used to generate second control instructions for managing and controlling the 3D printing process based on control instructions from the code generation module (150), so as to ensure printing accuracy and quality. Additive and subtractive material switching control module (230) is used to generate a third control instruction that coordinates the switching between additive and subtractive processes based on control instructions from code generation module (150); The subtractive manufacturing control module (240) is used to generate a fourth control instruction to perform the subtractive manufacturing task based on the control instructions from the code generation module (150); The measurement sensing control module (250) is used to monitor key indicators throughout the construction process by sending a fifth control command to the measurement sensing system (350) based on control commands from the code generation module (150), and to coordinate the adjustment of control commands of each module, including the motion control module (210), the 3D printing process control module (220), the additive / subtractive material switching control module (230), and the subtractive material construction control module (240), to ensure compliance with predetermined standards.

4. The intelligent construction system for irregularly shaped structures integrating additive and subtractive building materials as described in claim 3, characterized in that, A hybrid intelligent construction hardware system (300) includes: The robot system (310) is used to perform actual physical operations according to the first control command issued by the motion control module (210); The 3D printing system (320) is used to perform material printing in the additive manufacturing process based on the second control command issued by the 3D printing process control module (220); The additive-subtractive manufacturing switching system (330) is used to switch between the additive mode of the 3D printing robot system and the subtractive manufacturing mode of the subtractive building system according to the third control command issued by the additive-subtractive manufacturing switching control module (230). The subtractive manufacturing system (340) is used to implement the subtractive manufacturing process according to the fourth control command issued by the subtractive manufacturing control module (240); The metering sensing system (350) is used to collect data in real time, monitor the printing parameters, material parameters, geometric parameters and environmental parameters of the construction process, and send them to the metering sensing control module (250) to provide feedback to the metering sensing control module (250) and support closed-loop control.

5. A smart construction method integrating additive and subtractive building materials for irregularly shaped structures, characterized in that, The method of using the integrated intelligent construction system for adding and subtracting materials for irregular structures as described in any one of claims 1 to 4 includes: The HLC software system (100) is used to construct the virtual structure of the irregular structure through a hybrid layered construction, thereby obtaining the control instructions that the robot system can execute. The Hybrid Intelligent Construction (HIC) controller (200) performs integrated construction of irregular structures by adding or subtracting materials based on the control commands.

6. The intelligent construction method for irregularly shaped structures integrating additive and subtractive materials as described in claim 5, characterized in that, Virtual construction of irregular structures is performed using the hybrid layered construction HLC software system (100), resulting in control commands executable by the robot system, including: The complex three-dimensional digital model of the irregular structure is imported into the hybrid layered construction HLC software system (100). The integrity, tolerance and geometric requirements of the three-dimensional digital model are automatically checked by the model inspection and repair module (110), and any defects that may exist are repaired to form a repaired three-dimensional digital model that meets the requirements of material addition and subtraction. The feature analysis of the repaired irregular structure three-dimensional digital model is carried out by the additive and subtractive manufacturing feature recognition module (120). Based on the quality status of geometric specifications and processing features, the feature areas suitable for additive construction and the feature areas suitable for subtractive construction are identified, and the planning and feature sorting of the feature areas for additive construction and subtractive construction are set. Through the virtual construction and evaluation module (130), based on the planning and feature sorting of the feature areas of additive construction and subtractive construction, combined with the preset process library parameters, the entire manufacturing process is simulated; the stress concentration points between additive layers are predicted; the subtractive cutting trajectory is simulated, and optimization and adjustment are made according to the results to obtain the virtual construction results; Based on the results of virtual construction, the optimized manufacturing path and construction parameters are formulated through the path planning and parameter optimization module (140); The optimized manufacturing path and construction parameters are converted into control instructions that can be executed by the robot system through the code generation module (150).

7. The intelligent construction method for adding and subtracting materials to irregular structures as described in claim 6, characterized in that, The manufacturing path includes: a printing path and a subtractive manufacturing path.

8. The intelligent construction method for irregularly shaped structures integrating additive and subtractive materials as described in claim 6, characterized in that, The construction parameters include: Printing parameter P i This includes: printing speed, layer height h p and the time interval between printing layers; Subtractive processing parameters S j This includes: material reduction rate and material reduction depth hs; Robot system parameters R k This includes: target coordinates, target sequence, and robot movement speed.

9. The intelligent construction method for irregularly shaped structures integrating additive and subtractive materials as described in claim 6, characterized in that, The optimized manufacturing path and construction parameters satisfy equations (1)-(4), and for cases considering material utilization, they also satisfy equation (5): M(P i ,S j ,R k )=min∑(M Pm +M Sn ) (1) t(P i ,S j ,R k )=min∑(t Pm +t Sn ) (2) E(P i ,S j ,R k )=min∑(E Pm +E Sn ) (3) C(P i ,S j ,R k )=min∑(C Pm +C Sn ) (4) In the formula, P i It's the printing parameter, S j These are the parameters for subtractive processing, R. k是 Robot system parameters; M(P i ,S j ,R k ), t(P i ,S j ,R k ), E(P i ,S j ,R k ) and C(P i ,S j ,R k These are the minimum material consumption, minimum construction time, minimum energy consumption, and minimum cost, respectively. η(P i ,S j ,R k () represents the maximum material utilization rate; M Pm t Pm E Pm and C Pm The quantities are the material mass, printing time, printing energy consumption, and printing cost required for printing the feature region built by additive manufacturing, respectively. M Sn t Sn E Sn and C Sn These represent the material mass, subtractive processing time, subtractive processing energy consumption, and subtractive processing cost consumed in the feature region constructed using subtractive manufacturing, respectively. V(P i ,S j ,R k () represents the net volume of the final constructed structure; ρ(P i ,S j ,R k ) represents the material density.

10. The intelligent construction method for irregularly shaped structures integrating additive and subtractive materials as described in claim 6, characterized in that, The Hybrid Intelligent Construction (HIC) controller (200) performs integrated addition and subtraction construction of irregular structures based on the control commands, including: The additive / subtractive material switching control module (230) of the Hybrid Intelligent Construction HIC controller (200) sends a third control command to the additive / subtractive material switching system (330) in the Hybrid Intelligent Construction hardware system (300) to automatically switch to additive mode; The motion control module (210) sends a first control command to the robot system (310), and the 3D printing process control module (220) sends a second control command to the 3D printing system (320). The irregular structure ACS1 is printed according to the pre-planned path and printing parameters. During the printing process, the measurement and sensing control module (250) sends a fifth control command to the measurement and sensing system (350) to monitor the printing quality. After each NP layer is completed, the deviation between the geometric parameters and the model is monitored. If the deviation meets the set requirements, printing continues. If the deviation does not meet the requirements, the system automatically adjusts the printing parameters of the subsequent layers to compensate. (3) After the irregular structure ACS1 is printed, the third control command is sent to the additive and subtractive material switching system (330) through the additive and subtractive material switching control module (230) to automatically switch to the subtractive material mode; (4) The motion control module (210) sends the first control command to the robot system (310), and the subtractive construction control module (240) sends the fourth control command to the subtractive construction system (340). The subtractive part SCS1 of the irregular structure ACS1 is processed according to the pre-planned path and subtractive processing parameters. During the printing process, the measurement and sensing control module (250) sends the fifth control command to the measurement and sensing system (350) to monitor the quality of subtractive processing. After each NS layer is completed, the deviation between the geometric parameters and the model is monitored. If the deviation meets the set requirements, the subtractive processing continues. If the deviation does not meet the requirements, the system automatically adjusts the subtractive processing parameters of the subsequent layers to compensate. (5) Repeat steps (1) to (4) to print the irregular structure ACSm and perform subtractive processing on SCSn, and finally complete the construction of the irregular structure (400); (6) Obtain material addition and subtraction process data, process parameters, error compensation records and test reports through the metering sensing control module (250) for use in the delivery of printed products.

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