Systems and methods of shipbuilding

Abstract

To provide shipbuilding technology using robotic construction techniques that can reduce costs and time, and minimize errors. [Solution] The system for robotic construction of an ocean-going vessel includes a gantry and a robotic interface connected to the gantry, the gantry being configured to transport the robotic interface in at least two directions. A robot configured to perform construction work is releasably connected to the robotic interface. A robotic controller is positioned on the robot and configured to operate the robot. Controllers are operably connected to the gantry and the robotic interface, the controllers being configured to position the gantry, attach the robot to the robotic interface, and release the robot from the robotic interface.

Description

Technical Field

[0001] Field The subject matter of the present disclosure generally relates to systems, devices, and methods related to shipbuilding. More specifically, the present disclosure relates to manufacturing components of a ship using robotic assembly line type technology.

Background Art

[0002] Background The present disclosure relates to the field of shipbuilding. Specifically, the present disclosure relates to systems and methods for applying robotic assembly methods to the construction of components of a ship.

[0003] Large ocean vessels or ships are mostly built manually using various techniques such as welding and riveting. Small parts of the ship can be built using automated techniques, but the size and complexity of larger components typically require manual construction such as the construction of the structural components of the ship by the work of individual welders or riveters.

[0004] This results in increased costs and time, and errors in shipbuilding components caused by manual work can also be introduced. Robotic construction techniques can reduce costs and time, and reduce errors. Therefore, there is a need to improve shipbuilding technology using robotic construction techniques.

Summary of the Invention

[0005] In one embodiment, a system for robotic construction of an ocean-going vessel includes a gantry and a robotic interface connected to the gantry, the gantry configured to transport the robotic interface in at least two directions. A robot configured to perform construction work is releasably connected to the robotic interface. A robotic controller is located on the robot and configured to operate the robot. When the robot is removed from the gantry, the robotic controller remains on the robot. A controller is operationally connected to the gantry and the robotic interface, the controller configured to position the gantry, attach the robot to the robotic interface, and release the robot from the robotic interface.

[0006] In a further embodiment, the system includes a second robot, and the controller is configured to release the robot from the robot interface and to mount the second robot.

[0007] In a further embodiment, the robot includes an end effector releasably coupled to the robot, and the robot controller is configured to perform construction work using the end effector.

[0008] In a further embodiment, the robot includes a plurality of end effectors, each end effector configured to be releasably connected to the robot, and the robot controller is configured to perform construction work using at least one of the plurality of end effectors.

[0009] In a further embodiment, the gantry is configured to move the robot in at least three directions.

[0010] In further embodiments, the robot includes a material handling robot; a frame attached to the material handling robot; and a welding robot attached to the frame.

[0011] In a further embodiment, the welding robot is movably mounted to a frame, and a robot controller is operably connected to the welding robot to control its movement.

[0012] In one embodiment, a robotic construction method for an ocean-going vessel includes: moving a portion of the gantry to the robot; connecting the robot to the gantry using a robotic interface located on the gantry; controlling the robot using a robotic controller located on the robot to perform construction work on the ocean-going vessel; and separating the robot from the robotic interface, the robotic controller remaining on the robot after separation.

[0013] In a further embodiment, the method described above includes attaching a second robot to the robot interface after separating the robot from the robot interface.

[0014] In a further embodiment, the method described above includes performing the construction work using an end effector that is releasably coupled to a robot.

[0015] In a further embodiment, the method described above includes performing the construction work using at least two of a plurality of end effectors releasably coupled to a robot.

[0016] In a further embodiment, the gantry is configured to move the robot in at least three directions.

[0017] In a further embodiment, the robot includes a material handling robot; a frame attached to the material handling robot; and a welding robot attached to the frame; and the method further includes welding the ship components using the welding robot while handling the ship components using the material handling robot.

[0018] In a further embodiment, the welding robot is movably mounted to a frame, and this method further includes moving the welding robot during welding.

[0019] In one embodiment, a shipbuilding pin jig includes a jig base; a plurality of jacks fixed to the jig base, each jack having an actuator configured to extend and retract the jack; a sensor configured to detect the position of each of the plurality of jacks; and a controller operably connected to the plurality of jacks and sensors, the controller configured to actuate the plurality of jacks to predetermined positions based on data from the sensors.

[0020] In a further embodiment, each jack has a jack stop configured to prevent the jack from moving, and the jack stop and actuator are powered independently.

[0021] In a further embodiment, the sensor is further configured to detect contact between each jack and the workpiece,

[0022] In a further embodiment, the controller is configured to operate the jacks until each jack contacts the workpiece, thereby determining the shape of the workpiece.

[0023] In one embodiment, a method of using a pin jig to secure a ship component includes actuating a plurality of jacks fixed to a jack base to predetermined positions, each jack being actuated by an actuator controlled by a controller, the position of each jack being detected by a sensor; and fastening the ship component to the jacks.

[0024] In a further embodiment, the method includes fixing each jack to a predetermined position using a jack stop, the jack stop and the actuator being independently powered.

[0025] In a further embodiment, the method includes detecting contact between the jack and the ship component using a contact sensor, and actuating each jack until it contacts the workpiece to determine the shape of the workpiece, the contact between each jack and the ship component being determined using the contact sensor.

Brief Description of the Drawings

[0026] The accompanying drawings, which are incorporated herein and constitute a part of this specification, illustrate the present disclosure and, together with the description, serve to explain the principles thereof and to enable one skilled in the art to make and use it.

[0027] [Figure 1] FIG. 1 is a plan view of a gantry system by a robot for shipbuilding according to an embodiment. [Figure 2] FIG. 2 is a side view of a part of a gantry system by a robot for shipbuilding according to an embodiment. [Figure 3] FIG. 3 is a view of a robot for shipbuilding according to an embodiment. [Figure 4] FIG. 4 is a plan view of a pin jig for shipbuilding according to an embodiment. [Figure 5] FIG. 5 is a view of a robot for shipbuilding according to an embodiment.

[0028] In drawings, similar reference numbers generally indicate identical or similar elements. Additionally, generally, the leftmost digit of a reference number identifies the drawing in which that reference number first appears. [Modes for carrying out the invention]

[0029] Detailed explanation Here, we refer in detail to the representative embodiments shown in the attached drawings. References such as “one embodiment,” “a certain embodiment,” and “exemplary embodiment” indicate that the described embodiments may include certain features, structures, or characteristics, but not all embodiments necessarily include those particular features, structures, or characteristics. Furthermore, such phrasing does not necessarily refer to the same embodiment. Moreover, when certain features, structures, or characteristics are described in relation to a particular embodiment, it is considered within the knowledge of those skilled in the art that such features, structures, or characteristics will be affected in other embodiments, whether explicitly described or not.

[0030] Some embodiments of the present disclosure relate to a robotic assembly cell 100 for the construction of ship components. The robotic assembly cell 100 is designed to reduce assembly costs, part count, and complexity by allowing for the replacement or exchange of an entire assembly robot, which may be located on top of a gantry 102 as needed.

[0031] As shown in Figures 1 and 2, the basic components of the robotic assembly cell 100 include a robot 110 mounted on a gantry 102. In some embodiments, the gantry 102 is a multi-axis overhead gantry with a payload sufficient to transport the robot 110, associated support structures and control electronics, and the payload 112 of the robot 110. In some embodiments, as shown in Figure 2, the gantry 102 may be a three-axis gantry having a first track 102a and a second track 102b movably mounted on the first track 102a. A platform 103 is movably mounted on the second track 102b, which gives the platform 103 the ability to be positioned in two directions (e.g., x and y horizontal directions) as needed. Platform 103 is a base for a vertical actuator 104, which can move a gantry load interface 105 fixed to the vertical actuator 104 in a third vertical direction relative to a plane defined by a first track 102a and a second track 102b. This enables three-dimensional positioning of the gantry load interface 105 within the range of motion of the gantry 102. In some embodiments, the gantry 102 may allow the gantry load interface 105 to move in more or fewer directions. The movement of the components of the gantry 102 is controlled by a manufacturing controller 106 operably connected to the actuators and sensors of the gantry 102. The manufacturing controller 106 may include a processor and memory operably connected to a sensor 108 configured to detect the position of each component of the gantry 102. This enables the manufacturing controller 106 to position and move the gantry 102 as needed to accomplish manufacturing assembly operations.

[0032] The gantry load interface 105 is intended to releasably connect the robot 110 to the gantry 102. In some embodiments, the gantry load interface 105 is configured to quickly and reliably capture a corresponding robot interface 111 fixed to the robot 110. The gantry load interface 105 has sufficient capacity to secure both the robot 110 and the payload 112. The gantry load interface 105 can be automated and controlled by the manufacturing controller 106 for the connection and disconnection processes with the robot 110.

[0033] Robot 110 can be any suitable robot for manufacturing. Examples of manufacturing robots include those capable of performing welding, machining (e.g., drilling, cutting), fastening (e.g., riveting, tightening nuts or bolts), forming (e.g., bending or shaping metal), and other manufacturing steps. Each robot 110 will have a robot interface 111 that can be reliably connected to the gantry interface 104, as described above. As seen in Figure 3, the robot 110 is fixed to the robot interface 111 through a robot base 113, which is a support structure suitable for the rest of the robot 110. The robot 110 will also have a robot control 114, which is a controller that controls the electronic operation of the robot 110. In some embodiments, the robot control 114 is fixed to the robot base 113. This has the advantage of allowing the robot control 114 to remain permanently connected to the robot 110, even when the robot 110 is being replaced from the gantry 102. Disconnecting the robot control 114 from the robot 110 is a time-consuming and relatively complex task that often requires steps such as readjusting the robot 110 after completion. Therefore, leaving the robot control 114 connected to the robot 110 saves time and reduces the possibility of damage to the robot 110.

[0034] The robot 110 also includes a robotic mechanism 115 that houses various actuators and electromechanical elements that enable the robot 110 to function as needed. The robotic mechanism 115 is equipped with an end-effector interface 116 that enables the use of one or more end-effectors 117. These end-effectors 117 are tools that the robot 110 uses to perform its functions. Multiple end-effectors 117 may be housed in the robot 110 and can be replaced by the use of the end-effector interface 116 which is releasably connected to the end-effectors. Examples of end-effectors in various robots 110 may include fastening tools such as welding tips, riveting tools, nut sockets or screwdriver tips, handling tools such as magnets or vacuum attachments, sensors (e.g., cameras, lasers, eddy currents, and paint thickness sensors), grinding tools, cutting tools such as drills or milling heads, media blasting tools, blast media recovery tools, and laser ablation tools. The robot 110 also has appropriate sensors and actuators for performing assembly tasks using the above tools.

[0035] During use, multiple robots 110 can be stored in a ready state in an area accessible by the gantry 102. Each robot 110 may be configured to perform a different construction function. During construction, the gantry 102 operates the gantry load interface 105 to the robots 110 required for a given assembly step and attaches those robots 110 to the gantry 102. Once the operation of a robot 110 is complete, another robot 110 can be replaced in the same manner, enabling a continuous workflow for ship components. It should be understood that there may be multiple gantry 102s, each employing different robots 110, working on the same ship component.

[0036] Figure 4 shows an embodiment of an adjustable pin jig 400 that can be used to hold ship components in a desired shape. The pin jig 400 has an array of adjustable jacks 402 fixed to a flat base 404 that can be used to hold a flexible sheet of metal (or other suitable material) in a predetermined shape. Each jack 402 is operably connected to a pin jig controller 406 that can control the position of the jack 402. In this way, the controller 406 can actuate each jack 402 as needed to form the pin jig 400 into a desired shape. Components can then be placed on and fastened to the pin jig 400 to achieve the desired shape. In some embodiments, the controller 406 may receive input in the form of a pre-fabricated CAD model having the desired shape, which can then be used to control the jacks 402. In other embodiments, each jack 402 can have its position manually input to the controller 406.

[0037] The jack 402 may be electrically actuated or hydraulically actuated. In some embodiments, an independent jack lock may be present to lock and unlock the jack 402 in a predetermined position and to actuate the jack 402. This can improve safety and performance by reducing the possibility of a single failure that would cause movement of the jack 402. Appropriate sensors 408 may be provided to determine the position of each jack 402. The sensors 408 may be located inside (e.g., as a position encoder) or outside each jack 402, as a camera or other optical type positioning device.

[0038] In addition to being used to secure parts for construction purposes, the pin jig 400 can also be used to inspect finished parts and determine their shape. This is achieved by placing finished or semi-finished components in the pin jig 400 and then advancing each jack 402 until it contacts the component. In some embodiments, this contact can be detected by the aforementioned sensor 408. In other embodiments, certain additional sensors 408, such as electrical contact sensors, may be added to the pin jig 400. Once contact is made, the position of each jack 402 is recorded by the controller 406 and compared to a predetermined position to determine whether the shape of the finished part is correct. It should also be noted that this process occurs during the molding step and can measure the progress of the workpiece's completion.

[0039] Figure 5 shows an embodiment of robot 500 that combines material handling and welding functions. As described above, robot 110 can perform multiple functions, including welding. Holding the elements to be welded in the correct relative position during welding is part of the welding process. This can be difficult in the context of shipbuilding, as the parts to be welded are often large and heavy, and the geometry of ships, where space may be minimal, can complicate access to secure the parts. Robot 500 aims to solve these problems by presenting a combined material handling and welding robot. The basis for robot 500 is a handling robot 502 that includes an end effector 504 suitable for holding large elements such as hull plates using appropriate techniques such as magnets or vacuum. One or more additional welding robots 506 are mounted on a frame 505 fixed to robot 502. These welding robots 506 can perform the necessary welding work once robot 502 has secured the relevant components in place. In some embodiments, the welding robots 506 may be movable on appropriate tracks or arms fixed to robot 502 to improve welding performance. In this way, the robot 500 can perform welding operations on large components without requiring additional external support to weld components or position components for welding.

Claims

1. A system for the robotic construction of ocean-going vessels, the system being: Having a gantry; The gantry has a robot interface connected to it, and the gantry is configured to transport the robot interface in at least two directions; The robot has a robot that is releasably connected to the robot interface and configured to perform construction work; The robot has a robot controller that is positioned on the robot and configured to operate the robot, the robot controller remaining on the robot when the robot is removed from the gantry; and, The system has a controller operably connected to the gantry and the robot interface, the controller being configured to position the gantry, attach the robot to the robot interface, and release the robot from the robot interface. The aforementioned system.

2. The system according to claim 1, further comprising a second robot, wherein the controller is configured to release the robot from the robot interface and to attach the second robot.

3. The system according to claim 1, wherein the robot has an end effector that is releasably connected to the robot, and the robot controller is configured to perform the construction work using the end effector.

4. The system according to claim 1, wherein the robot has a plurality of end effectors, each end effector is configured to be releasably connected to the robot, and the robot controller is configured to perform the construction work using at least one of the plurality of end effectors.

5. The system according to claim 1, wherein the gantry is configured to move the robot in at least three directions.

6. The aforementioned robot further: It has a material handling robot; It has a frame attached to the material handling robot; and, The frame has a welding robot attached to it. The system according to claim 1.

7. The system according to claim 6, wherein the welding robot is movably mounted on the frame, and the robot controller is operably connected to the welding robot to control the movement of the welding robot.

8. A method for constructing ocean-going vessels using robots, the method being: It has the capability to move a part of the gantry to the robot; The robot is connected to the gantry using a robot interface located on the gantry; The robot is controlled using a robot controller positioned on the robot to perform construction work on the ocean vessel; The robot is separated from the robot interface, and the robot controller remains attached to the robot after the separation. The aforementioned method.

9. The method according to claim 8, further comprising attaching a second robot to the robot interface after separating the robot from the robot interface.

10. The method according to claim 8, further comprising performing the construction work using an end effector releasably connected to the robot.

11. The method according to claim 10, further comprising performing the construction work using at least two of a plurality of end effectors releasably connected to the robot.

12. The method according to claim 8, wherein the gantry is configured to move the robot in at least three directions.

13. The aforementioned robot further: It has a material handling robot; It has a frame attached to the material handling robot; and, The frame has a welding robot attached to it; and, The method further includes welding the ship components using a welding robot while handling the ship components using the material transport robot. The method according to claim 1.

14. The method according to claim 13, wherein the welding robot is movably mounted on the frame, and the method further comprises moving the welding robot during welding.

15. A pin jig for shipbuilding, wherein the pin jig is: Having a jig base; The jig base has a plurality of jacks fixed to it, each jack having an actuator configured to extend and retract the jack; It has a sensor configured to detect the position of each of the aforementioned plurality of jacks; and, The system has a controller operably connected to the aforementioned plurality of jacks and the aforementioned sensors, and the controller is configured to operate the plurality of jacks to predetermined positions based on data from the sensors. The aforementioned pin jig.

16. The pin jig according to claim 15, wherein each jack has a jack stop configured to prevent the movement of the jack, and the jack stop and the actuator are powered independently.

17. The sensor is further configured to detect contact between each jack and the workpiece, The controller is configured to operate each jack until it contacts the workpiece, and to determine the shape of the workpiece. The pin jig according to claim 15.

18. A method for securing ship components using pin jigs, the method being: The system involves moving multiple jacks fixed to a jack base to predetermined positions, each jack being operated by an actuator controlled by a controller, and the position of each jack being sensed by a sensor; and, The ship components are fastened to the jacks. The aforementioned method.

19. The method according to claim 18, further comprising using jack stops to fix each jack in a predetermined position, wherein the jack stops and the actuators are powered independently.

20. To detect contact between the jack and the ship's components using a contact sensor, and, The system further includes operating each jack until it contacts the workpiece to determine the shape of the workpiece, and the contact between each jack and the ship component is determined using a contact sensor. The method according to claim 18.

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