Autonomous construction site rover for terrain mapping and safety monitoring

Abstract

Autonomous construction site rover with a chassis, a drive system, a multi-sensor system, an AI processing unit, a power supply and a communication unit for autonomous terrain mapping and hazard detection.

Description

SCOPE OF THE INVENTION

[0001] The present invention relates to an autonomous robotic monitoring system for active construction sites. In particular, the invention discloses an AI-supported construction site rover designed for autonomous navigation, terrain mapping, hazard detection, environmental monitoring, and safety monitoring. The system integrates multiple sensor systems, machine learning algorithms, and wireless communication interfaces into a robust mobile platform to continuously monitor construction site conditions, identify unsafe areas, and document construction progress without human intervention. SUMMARY

[0002] An autonomous construction site rover is described, comprising a robust chassis, an all-terrain drive system, and a multi-layered sensor system, including a LiDAR sensor, stereo cameras, a panoramic camera, a thermal imaging camera, ultrasonic distance sensors, gas sensors, vibration sensors, ambient light and dust sensors, and a GPS / GNSS module. An integrated AI processing unit performs sensor fusion, SLAM-based navigation, terrain mapping, and predictive hazard analysis. The rover autonomously patrols construction sites, detects unsafe terrain, incomplete structures, environmental hazards, and operational risks, and transmits alerts and data in real time via wireless communication interfaces. The invention significantly improves workplace safety and increases the efficiency of construction site monitoring. TECHNICAL AREA OF INVENTION

[0003] The invention lies in the field of autonomous robotic systems and construction site safety. It relates in particular to an AI-supported autonomous construction site rover that uses sensor fusion, machine learning, and real-time communication for terrain mapping, hazard detection, safety monitoring, and documentation of construction progress. STATE OF THE ART

[0004] Construction sites represent highly dynamic environments characterized by changing terrain, moving machinery, human activity, and constantly evolving construction conditions. Known monitoring solutions have several drawbacks, including: • Dependence on manual safety inspections • Limited terrain detection and mapping capability • Lack of real-time hazard prediction • Insufficient integration of visual, thermal, environmental, and structural sensors • Use of static cameras or remotely controlled systems without autonomy

[0005] Existing robotic systems are mostly limited to simple monitoring tasks or manually controlled functions and do not offer autonomous navigation, predictive safety analysis, or comprehensive sensor integration. Therefore, there is a need for an intelligent, robust, and autonomous rover for continuous safety monitoring and environmental analysis on construction sites. SUMMARY OF THE INVENTION

[0006] The present invention provides an autonomous construction site rover for continuous safety monitoring and terrain analysis. Key features of the invention are: 1. A robust, low-centered chassis for uneven terrain 2. An all-terrain drive system with independently driven wheels or tracks 3. A LiDAR-based system for 3D terrain mapping and SLAM navigation 4. Multiple camera modules for depth detection and all-round view 5. Thermal, gas-based, vibration-based and environmental sensors for hazard detection 6. An AI-powered hazard prediction and decision engine 7. Wireless real-time communication for alerting and data transmission 8. A self-diagnostic and safety shutdown concept

[0007] The rover moves autonomously through construction sites, generates real-time terrain maps, detects hazardous conditions and transmits warning messages to responsible authorities. DETAILED DESCRIPTION OF THE INVENTION 1. Mechanical structure and chassis

[0008] The rover features a robust chassis made of corrosion-resistant metal alloys, reinforced by impact-resistant polymer covers. The chassis is designed with a low center of gravity to ensure stability on inclined and uneven surfaces.

[0009] The mechanical structure includes: • Off-road wheels or tracks, each with independent electric motors for differential steering • Independent suspension elements for shock absorption and sensor alignment • A central vertical mast to accommodate optical sensors and antennas • Protective bars and bumpers to protect sensors and electronics

[0010] This design allows navigation across sand, gravel, mud, debris, trenches and scaffolding areas. 2. Sensor architecture2.1 LiDAR sensor

[0011] A 3D LiDAR sensor is mounted in the upper front area of ​​the chassis and generates a 360-degree point cloud for obstacle detection, SLAM navigation and terrain reconstruction. 2.2 Stereo cameras

[0012] A pair of stereo cameras is mounted on the front of the rover with a defined baseline to capture depth information for detecting differences in elevation, trenches, and structural obstacles. 2.3 Panoramic camera

[0013] A 360-degree panoramic camera is mounted on the central mast, enabling seamless visual monitoring of the surroundings. 2.4 Thermal imaging camera

[0014] A thermal imaging camera is mounted on the side of the chassis and is used to detect heat anomalies such as overheated machinery or fire hazards. 2.5 Ultrasonic sensors

[0015] Several ultrasonic sensors are integrated into the front, rear and side areas to detect short-distance obstacles even in dusty or poor visibility conditions. 2.6 Gas sensors

[0016] Gas sensors for the detection of VOCs, methane and carbon monoxide are arranged in a ventilated, protected compartment. 2.7 Vibration sensors

[0017] Vibration and acceleration sensors are mounted directly on the chassis and detect ground instability or structural resonances. 2.8 Ambient light and dust sensors

[0018] Sensors for light intensity and particle concentration assess visibility conditions and dust levels. 2.9 GPS / GNSS module

[0019] A GPS / GNSS receiver is positioned in the upper housing and provides precise position data. 3. Electronics and control system

[0020] The electronic system includes: • a central CPU / GPU processing unit for AI calculations • an edge AI accelerator for real-time object recognition • a SLAM processing module • a hazard analysis engine for detecting unstable terrain, open trenches, incomplete structures and environmental hazards

[0021] All sensors are connected via a high-speed data bus, while a CAN bus controls the motor and energy management. 4. Energy supply

[0022] The power supply is provided by a sealed lithium-ion battery with: • Battery Management System (BMS) • Integrated solar charging platform on the top of the rover • Energy-saving modes during inactive phases 5. Communication interfaces

[0023] The rover features: • 5G / LTE module • WLAN interface • Bluetooth module • LoRa radio module

[0024] These ensure reliable data transmission under different network conditions. 6. Functionality 6.1 System startup

[0025] When switched on, the rover performs a self-diagnosis of all sensors, drives and processors. 6.2 Autonomous Navigation

[0026] The rover navigates autonomously using fused LiDAR, camera and SLAM data. 6.3 Hazard detection

[0027] The KL engine detects physical, mechanical, and environmental hazards and sends warning messages. 6.4 Data storage

[0028] Sensor data is stored locally and regularly synchronized with a remote server. ADVANTAGES OF THE INVENTION 1. Fully autonomous construction site monitoring 2. Real-time detection of terrain and environmental hazards 3. Increased workplace safety 4. Robust operation under extreme construction site conditions 5. Automated documentation of construction progress INDUSTRIAL APPLICABILITY

[0029] The invention is particularly suitable for construction sites, infrastructure projects, industrial plants, mines and large construction sites where continuous, autonomous safety monitoring is required.

Claims

[1] Autonomous construction site rover with a chassis, a drive system, a multiple sensor system, an AI processing unit, a power supply and a communication unit for autonomous terrain mapping and hazard detection. [2] Rover according to claim 1, wherein the LiDAR sensor generates a 3D point cloud for SLAM navigation. [3] Rover according to claim 1, wherein the stereo cameras are used for depth detection of terrain differences. [4] Rover according to claim 1, wherein the panoramic camera enables 360-degree monitoring. [5] Rover according to claim 1, wherein the thermal imaging camera detects heat anomalies. [6] Rover according to claim 1, wherein gas sensors detect VOCs, methane and carbon monoxide. [7] Rover according to claim 1, wherein vibration sensors detect ground instability. [8] Rover according to claim 1, wherein the power supply comprises a lithium-ion battery and a solar charging platform. [9] Rover according to claim 1, wherein the communication unit comprises at least two interfaces from 5G / LTE, WLAN, Bluetooth and LoRa. [10] Rover according to claim 1, wherein the AI ​​processing unit comprises a hazard prediction engine for detecting unsafe construction conditions.