Systems, methods and devices for magnetic fixturing during automated assembly of building structures

Abstract

Embodiments herein generally relate to systems, methods, and devices for magnetic fixturing during automated assembly of building structures. In at least one embodiment, there is provided a magnetic fixture to position a building component on an assembly surface during automated assembly by an assembly robot. The magnetic fixture comprises: a magnet toggleable between an ON state and an OFF state; and a fixture frame coupled to the magnet. The fixture frame comprises a coupling member to form a detachable connection with a positioning assembly attached to the building component; and a gripping member having one or more gripping surfaces for gripping by the assembly robot, the assembly robot being configured to move the magnetic fixture to control the position of the building component on the building surface.

Description

SYSTEMS, METHODS AND DEVICES FOR MAGNETIC FIXTURING DURING AUTOMATED ASSEMBLY OF BUILDING STRUCTURESCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of United States Provisional Patent Application No. 63 / 667,858 filed July 5, 2024, and the entire content of United States Provisional Patent Application No. 63 / 667,858 is incorporated by reference herein.FIELD

[0002] The present disclosure generally relates to assembly and manufacturing of building structures, including building structures used in the assembly of housing units as well as other infrastructure. The present disclosure relates, in particular, to systems, methods, and devices for magnetic fixturing during automated assembly of building structures.INTRODUCTION

[0003] The following is not an admission that anything discussed below is part of the prior art or part of the common general knowledge of a person skilled in the art.

[0004] Automated assembly of building structures using assembly robots can present many engineering, logistical, and practical challenges. The building components used to assemble the building structure can have a wide variety of sizes, shapes and configurations. For example, prefabricated building components (PBCs) such as wall panels, floor cassettes, roof trusses, stairway components can have a wide variety of sizes, shapes and configurations. Furthermore, strict dimensional accuracy and quality targets may have to be met during the automated assembly of the building structures. Accordingly, there is a need for a fixturing system, device or method to overcome and address the shortcomings of conventional solutions.SUMMARY

[0005] The following introduction is provided to introduce the reader to the more detailed discussion to follow. The introduction is not intended to limit or define any claimed or as yet unclaimed invention. One or more inventions may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document including its claims and figures.

[0006] In one broad aspect, there is provided a magnetic fixture to position a building component on an assembly surface during automated assembly by an assembly robot. The magnetic fixture comprises a magnet and a fixture frame coupled to the magnet. The magnet is toggleable between an ON state and an OFF state. The fixture frame comprises a coupling member to form a detachable connection with a positioning assembly attached to the building component; and a gripping member having one or more gripping surfaces for gripping by the assembly robot. The assembly robot is configured to move the magnetic fixture to control the position of the building component on the building surface.

[0007] In another broad aspect, there is provided a positioning assembly to position a building component on an assembly surface during automated assembly by an assembly robot. The positioning assembly comprises an assembly frame and a fixture coupler. The assembly frame includes an attachment means for attachment of the positioning assembly to the building component. The fixture coupler forms a detachable connection with a magnetic fixture. The assembly robot is configured to move the magnetic fixture to control the position of the building component on the building surface.

[0008] In another broad aspect, there is provided an apparatus for positioning a building component on an assembly surface during automated assembly by an assembly robot. The apparatus comprises a magnetic fixture and a positioning assembly. The magnetic fixture includes any magnetic fixture disclosed herein. The positioning assembly includes any positioning assembly disclosed herein.

[0009] In another broad aspect, there is provided a method of use of magnetic fixtures for positioning a building component on an assembly surface during automatedassembly by an assembly robot. The method comprises: determining a current position of the building component on the assembly surface in relation to a target position, one or more positioning assemblies being attached to the building component; determining if a repositioning is needed so that the building component is in the target position; in response to determining that a repositioning is needed, moving a magnetic fixture to a predetermined position, wherein the magnetic fixture is connected to at least one of the one or more positioning assemblies; and toggling a magnet of the magnetic fixture from an OFF state to an ON state to secure the building component in the target position.

[0010] In another broad aspect, there is provided a magnetic fixture to support building components during automated assembly. The magnetic fixture comprises: a magnet toggleable between an ON state and an OFF state; and a fixture frame attached to the magnet, the fixture frame comprising one or more frame surfaces to support the building components during the automated assembly.

[0011] In another broad aspect, there is provided a system for automated assembly of a building structure. The system comprises one or more magnetic fixtures, each magnetic fixture according to any one of the example embodiments described herein; and a gripper assembly mountable to an assembly robot configured for the automated assembly of the building structure, the gripper assembly comprising one or more gripper jaws to grip the one or more magnetic fixtures.

[0012] In another broad aspect, there is provided a method of use of magnetic fixtures to support building components on an assembly table during automated assembly of a building structure. The method comprises: analyzing assembly data associated with the building structure to determine a magnetic fixture arrangement to support the building components during automated assembly of the building structure, the determined magnetic fixture arrangement including at least one of a number, a type, an assembly table position, an assembly table orientation, and a sequence of positioning and removal of the magnetic fixtures; positioning the magnetic fixtures on the assembly table based on the determined magnetic fixture arrangement; positioning the building components on the assembly table using the magnetic fixtures to support the building components;assembling the building components to form the building structure; and removing the magnetic fixtures from the assembly table.

[0013] Other features and advantages of the present application will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the application, are given by way of illustration only and the scope of the claims should not be limited by these embodiments, but should be given the broadest interpretation consistent with the description as a whole.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] For a better understanding of the embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings which show at least one exemplary embodiment, and in which:

[0015] FIG. 1A is a front perspective schematic diagram of a magnetic fixture to support building components during automated assembly, in accordance with an embodiment;

[0016] FIG. 1 B is a rear perspective schematic diagram of the magnetic fixture of FIG. 1A;

[0017] FIG. 1 C is a front perspective schematic diagram of a magnetic fixture to support building components during automated assembly, in accordance with another embodiment;

[0018] FIG. 1 D is a front perspective schematic diagram of a magnetic fixture to support building components during automated assembly, in accordance with another embodiment;

[0019] FIG. 2 is a perspective schematic diagram of a magnetic fixture, in accordance with another embodiment;

[0020] FIG. 3 is a perspective schematic diagram of magnetic fixtures, in accordance with another embodiment;

[0021] FIG. 4 is a top view schematic diagram of magnetic fixtures, in accordance with another embodiment;

[0022] FIG. 5 is a perspective schematic diagram of the magnetic fixtures of FIG. 4 in use with building components;

[0023] FIG. 6A a partial perspective schematic diagram of a magnetic fixture, in accordance with another embodiment;

[0024] FIG. 6B is a partial perspective schematic diagram of a magnetic fixture, in accordance with another embodiment;

[0025] FIG. 7 is a partial front view schematic diagram of the magnetic fixture of FIG. 6B being gripped by the gripper jaws of a gripper mounted to an assembly robot;

[0026] FIG. 8 is another partial perspective schematic diagram of the magnetic fixture of FIG. 6B;

[0027] FIG. 9A is a schematic diagram of the gripper jaws of a gripper mounted to an assembly robot moved to a position to grip / pick-up a magnetic fixture, in accordance with an embodiment;

[0028] FIG. 9B is a schematic diagram of the gripper jaws of FIG. 9A moved to another position to grip / pick-up the magnetic fixture shown in FIG. 9A;

[0029] FIG. 10 is a perspective schematic diagram of a robotic manipulator tool, in accordance with an embodiment;

[0030] FIG. 11 is a perspective schematic diagram of a magnet actuator of the robotic manipulator tool of FIG. 10 toggling a magnet of a magnetic fixture from an OFF state to an ON state;

[0031] FIG. 12A is a perspective schematic diagram of a magnet actuator, in accordance with another embodiment for toggling a magnet of a magnetic fixture from an ON state to an OFF state;

[0032] FIG. 12B is a perspective schematic diagram of the magnet actuator of FIG. 12A engaged in toggling the magnet of FIG. 12A from the ON state to the OFF state;

[0033] FIG. 13A is a perspective schematic diagram of a magnet actuator, in accordance with another embodiment for toggling a magnet of a magnetic fixture from an ON state to an OFF state;

[0034] FIG. 13B is a perspective schematic diagram of the magnet actuator of FIG. 13A engaged in toggling the magnet of FIG. 13A from the ON state to the OFF state;

[0035] FIG. 13C is another perspective schematic diagram of the magnet actuator of FIG. 13A engaged in toggling the magnet of FIG. 13A from the ON state to the OFF state;

[0036] FIG. 14A is a perspective schematic diagram of a storage unit, in accordance with an embodiment;

[0037] FIG. 14B is a perspective schematic diagram of the storage unit of FIG. 14A storing multiple magnetic fixtures;

[0038] FIG. 15 is a partial perspective schematic diagram of the storage unit of FIG. 14A including storage sensors, in accordance with an embodiment;

[0039] FIG. 16A is a flowchart showing a method of use of magnetic fixtures to support building components on an assembly table during automated assembly of a building structure, in accordance with an embodiment;

[0040] FIG. 16B is a flowchart showing a method of use of magnetic fixtures to support building components on an assembly table during automated assembly of a building structure, in accordance with another embodiment;

[0041] FIG. 16C is a flowchart showing a method of use of magnetic fixtures to support building components on an assembly table during automated assembly of a building structure, in accordance with another embodiment;

[0042] FIG. 17 is a schematic diagram showing a system for automated assembly of building structures, in accordance with an embodiment;

[0043] FIG. 18 is a schematic diagram showing a robotic assembly cell, in accordance with an embodiment;

[0044] FIG. 19 is a schematic diagram showing an example overhanging subfloor section requiring fixture support during assembly;

[0045] FIG. 20 is a schematic diagram showing an example overhanging subfloor section not requiring fixture support during assembly;

[0046] FIG. 21 is a schematic diagram showing example floor cassettes that may be supported during assembly using one or more fixtures;

[0047] FIG. 22 is a schematic diagram of a joist supported by multiple magnetic fixtures during assembly, in accordance with an embodiment;

[0048] FIG. 23 is a schematic diagram showing a magnetic fixture arrangement of multiple magnetic fixtures around the perimeter of a floor cassette, in accordance with an embodiment;

[0049] FIG. 24 is a schematic diagram showing an example floor cassette;

[0050] FIG. 25 is a schematic diagram showing an example scenario, where a joist is open-ended on one side, but is required to be nailed to rim boards on the other side;

[0051] FIG. 26 is a front perspective schematic diagram of a magnetic fixture, in accordance with another embodiment;

[0052] FIG. 27A is a perspective schematic diagram of a positioning assembly, in accordance with an embodiment;

[0053] FIG. 27B is a perspective schematic diagram of the positioning assembly of FIG. 27A attached to a building component;

[0054] FIG. 28A is a perspective schematic diagram of a positioning assembly, in accordance with another embodiment;

[0055] FIG. 28B is a perspective schematic diagram of the positioning assembly of FIG. 28A attached to a building component;

[0056] FIG. 29A is a perspective schematic diagram of a positioning assembly, in accordance with another embodiment;

[0057] FIG. 29B is a perspective schematic diagram of the positioning assembly of FIG. 29A attached to a building component;

[0058] FIG. 30A is a perspective schematic diagram of an apparatus for positioning a building component on an assembly surface during automated assembly by an assembly robot, in accordance with an embodiment;

[0059] FIG. 30B is a top view schematic diagram of the apparatus of FIG. 30A;

[0060] FIG. 30C is a side view schematic diagram of the apparatus of FIG. 30A;

[0061] FIG. 31 is a perspective view of a robotic manipulator tool, in accordance with an embodiment;

[0062] FIG. 32 is a flowchart showing a method of use of magnetic fixtures for positioning a building component on an assembly surface during automated assembly by an assembly robot, in accordance with an embodiment;

[0063] FIG. 33 is a schematic diagram of an example partially assembled floor cassette on an assembly surface;

[0064] FIG. 34 is a flowchart showing a method of attachment of positioning assemblies to a building component, in accordance with an embodiment;

[0065] FIG. 35A is a schematic diagram of an example floor cassette and the determined attachment locations of positioning assemblies, in accordance with an embodiment of the method of FIG. 34;

[0066] FIG. 35B is a schematic diagram of another example floor cassette and the determined attachment locations of positioning assemblies, in accordance with an embodiment of the method of FIG. 34;

[0067] FIG. 35C is a schematic diagram of the example floor cassette of FIG. 35A and the determined attachment locations of positioning assemblies, in accordance with another embodiment of the method of FIG. 34;

[0068] FIG. 35D is a schematic diagram of the example floor cassette of FIG. 35A and the determined attachment locations of positioning assemblies, in accordance with another embodiment of the method of FIG. 34;

[0069] FIG. 36A is a schematic diagram of another example floor cassette having multiple positioning assemblies attached to the floor cassette, in accordance with an embodiment;

[0070] FIG. 36B is a schematic diagram of the floor cassette of FIG. 36A with magnetic fixtures connected to each of the multiple positioning assemblies; and

[0071] FIGS. 37A-37C are example captured images of a positioning assembly having multiple vision targets, in accordance with an embodiment.

[0072] Further aspects and features of the example embodiments described herein will appear from the following description taken together with the accompanying drawings.DESCRIPTION OF VARIOUS EMBODIMENTS

[0073] Various embodiments in accordance with the teachings herein will be described below to provide an example of at least one embodiment of the claimed subject matter. No embodiment described herein limits any claimed subject matter. The claimed subject matter is not limited to devices, systems or methods having all of the features of any one of the devices, systems or methods described below or to features common to multiple or all of the devices, systems or methods described herein. It is possible that there may be a device, system or method described herein that is not an embodiment of any claimed subject matter. Any subject matter that is described herein that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such subject matter by its disclosure in this document.

[0074] For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition,numerous specific details are set forth in order to provide a thorough understanding of the subject matter described herein. However, it will be understood by those of ordinary skill in the art that the subject matter described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the subject matter described herein. The description is not to be considered as limiting the scope of the subject matter described herein.

[0075] It should also be noted that the terms “coupled” or “coupling” as used herein can have several different meanings depending in the context in which these terms are used. For example, the terms coupled or coupling can have a mechanical, fluidic or electrical connotation. For example, as used herein, the terms coupled or coupling can indicate that two elements or devices can be directly connected to one another or connected to one another through one or more intermediate elements or devices via an electrical or magnetic signal, electrical connection, an electrical element or a mechanical element depending on the particular context. Furthermore, coupled electrical elements may send and / or receive data.

[0076] Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is, as “including, but not limited to”.

[0077] It should also be noted that, as used herein, the wording “and / or” is intended to represent an inclusive-or. That is, “X and / or Y” is intended to mean X or Y or both, for example. As a further example, “X, Y, and / or Z” is intended to mean X or Y or Z or any combination thereof.

[0078] Some elements herein may be identified by a part number, which is composed of a base number followed by an alphabetical or subscript-numerical suffix (e.g., 112a, or 112i). Multiple elements herein may be identified by part numbers that share a base number in common and that differ by their suffixes (e.g., 112i, 1122, and112s). All elements with a common base number may be referred to collectively or generically using the base number without a suffix (e.g., 112).

[0079] It should be noted that terms of degree such as "substantially", "about" and "approximately" as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree may also be construed as including a deviation of the modified term, such as by 1 %, 2%, 5% or 10%, for example, if this deviation does not negate the meaning of the term it modifies.

[0080] Furthermore, the recitation of numerical ranges by endpoints herein includes all numbers and fractions subsumed within that range (e.g. 1 to 5 includes 1 , 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also to be understood that all numbers and fractions thereof are presumed to be modified by the term "about" which means a variation of up to a certain amount of the number to which reference is being made if the end result is not significantly changed, such as 1 %, 2%, 5%, or 10%, for example.

[0081] Reference throughout this specification to “one embodiment”, “an embodiment”, “at least one embodiment” or “some embodiments” means that one or more particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments, unless otherwise specified to be not combinable or to be alternative options.

[0082] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its broadest sense, that is, as meaning “and / or” unless the content clearly dictates otherwise.

[0083] Similarly, throughout this specification and the appended claims the term “communicative” as in “communicative pathway,” “communicative coupling,” and in variants such as “communicatively coupled,” is generally used to refer to any engineered arrangement for transferring and / or exchanging information. Exemplary communicative pathways include, but are not limited to, electrically conductive pathways (e.g., electrically conductive wires, electrically conductive traces), magnetic pathways (e.g., magnetic media), optical pathways (e.g., optical fiber), electromagnetically radiative pathways (e.g.,radio waves), or any combination thereof. Exemplary communicative couplings include, but are not limited to, electrical couplings, magnetic couplings, optical couplings, radio couplings, or any combination thereof.

[0084] Throughout this specification and the appended claims, infinitive verb forms are often used. Examples include, without limitation: “to detect,” “to provide,” “to transmit,” “to communicate,” “to process,” “to route,” and the like. Unless the specific context requires otherwise, such infinitive verb forms are used in an open, inclusive sense, that is as “to, at least, detect,” to, at least, provide,” “to, at least, transmit,” and so on.

[0085] The example systems and methods described herein may be implemented as a combination of hardware or software. In some cases, the examples described herein may be implemented, at least in part, by using one or more computer programs, executing on one or more programmable devices comprising at least one processing element, and a data storage element (including volatile memory, non-volatile memory, storage elements, or any combination thereof). These devices may also have at least one input device (e.g. a keyboard, mouse, touchscreen, or the like), and at least one output device (e.g. a display screen, a printer, a wireless radio, or the like) depending on the nature of the device.

[0086] Some elements that are used to implement at least part of the systems, methods, and devices described herein may be implemented via software that is written in a high-level procedural language such as object-oriented programming. The program code may be written in C++, C#, JavaScript, Python, or any other suitable programming language and may comprise modules or classes, as is known to those skilled in object- oriented programming. Alternatively, or in addition thereto, some of these elements implemented via software may be written in assembly language, machine language, or firmware as needed. In either case, the language may be a compiled or interpreted language.

[0087] At least some of these software programs may be stored on a computer readable medium such as, but not limited to, a ROM, a magnetic disk, an optical disc, a USB key, and the like that is readable by a device having at least one processor, anoperating system, and the associated hardware and software that is used to implement the functionality of at least one of the methods described herein. The software program code, when read by the device, configures the device to operate in a new, specific, and predefined manner (e.g., as a specific-purpose computer) in order to perform at least one of the methods described herein.

[0088] Furthermore, at least some of the programs associated with the systems and methods described herein may be capable of being distributed in a computer program product including a computer readable medium that bears computer usable instructions for one or more processors. The medium may be provided in various forms, including non-transitory forms such as, but not limited to, one or more diskettes, compact disks, tapes, chips, and magnetic and electronic storage. Alternatively, the medium may be transitory in nature such as, but not limited to, wire-line transmissions, satellite transmissions, internet transmissions (e.g. downloads), media, digital and analog signals, and the like. The computer useable instructions may also be in various formats, including compiled and non-compiled code.

[0089] There is a need for an improved fixturing system, device or method for use during an automated assembly of building structures using building components to support such building components and / or locate the building components during the assembly. The improved fixturing system, device or method used during automated assembly of building structures must be sufficiently flexible to support the wide variety of sizes, shapes and configurations of the building components. Additionally, the fixturing system, device or method must enable meeting the strict dimensional accuracy and quality targets for the automated assembly of the building structures.

[0090] Disclosed herein are systems, methods, and devices for magnetic fixturing during automated assembly of building structures. The disclosed systems, methods, and devices for magnetic fixturing can provide full flexibility in the position, orientation, and configuration of the fixturing solution, while still enabling high positional accuracy of the building components. The magnetic fixtures can be positioned at any location on an assembly table and the magnets can ensure that the fixtures remain in place until the magnets are later deactivated by the assembly robot.

[0091] Other fixturing systems and methods may only be capable of handling specific subsets of PBC configurations due to the inherent inflexibility of the underlying hardware and / or software. Other fixturing systems and methods may rely on fixturing pins or features that are only adjustable in one or two axes. PBC configurations that fall outside of the system’s capability may typically be assembled manually or semi-manually. For example, there does not appear to be a commercially-available solution for fully automated floor cassette assembly, likely due in large part to the challenge in developing a fixturing system flexible enough to capture an acceptable subset of configurations.

[0092] In contrast, the disclosed systems, methods, and devices include magnetic fixtures that enable the fixtures to be positioned in a large variety of configurations based on the requirements of the PBCs being assembled. The magnetic fixtures may be adjustable along all three axes to provide superior positioning flexibility compared with other fixturing systems.

[0093] Furthermore, the disclosed magnetic fixtures may be automatically positioned using robots to provide a higher level of precision compared with manual positioning of the fixtures. This can enable high-quality assembly of building structures.

[0094] Additionally, the assembly robots can be configured to automatically retrieve the magnetic fixtures from a storage unit when needed for assembly of the building structure. The assembly robots can be further configured to retrieve the magnetic fixtures from the assembly table after the assembly is complete and return the magnetic fixtures to the storage unit. This can enable the entire assembly process to be fully autonomous from set-up to clean-up, thereby improving efficiency and cycle time of the assembly process.

[0095] Furthermore, the disclosed systems, methods, and devices include software or processor-executable instructions that can analyze a model of a building structure and determine the optimal number / quantity, combination, configuration, and sequence of the magnetic fixtures to enable assembling the building structure with high accuracy, high efficiency and short cycle time. The determined combination,configuration, and sequence of the magnetic fixtures may be translated into assembly robot instructions.

[0096] The assembly robots can execute the assembly robot instructions to autonomously position the magnetic fixtures on the assembly table for assembling the building structure. After each magnetic fixture is positioned on the assembly table, the assembly robot can automatically toggle the corresponding magnet of that magnetic fixture to an ON state, effectively locking the magnetic fixture in its position. In this way, a completely unique and specialized fixturing configuration can be generated for each building structure being assembled, with the assembly robots simply rearranging and reconfiguring the magnetic fixtures between assembling different structures. This provides the flexibility required to handle the wide variety of sizes, shapes and configurations of the building components and building structures. Further, the assembly robots can autonomously remove the magnetic fixtures after the assembly process is complete. The software or processor-executable instructions may further perform validations and interference checks to enable early detection of modeling errors and / or avoid assembly robot collisions during the assembly process.

[0097] In some instances, a building component (e.g., a partially assembled floor cassette, wall panel or roof truss) may be transferred to the assembly table from a different location. If the position of the transferred building component is not accurately controlled, further assembly may need to be performed using position offsets with reference to the position of the transferred building component. For example, motion control commands for assembly robots may be defined with reference to a target position of the building component on the assembly table. But the motion control commands may need to be updated based on the actual position of the transferred building component on the assembly table.

[0098] The disclosed systems, methods and devices can mitigate this problem by enabling position control of the transferred building component. The disclosed magnetic fixture can form a detachable connection with a positioning assembly attached to the building component. An assembly robot can move the magnetic fixture to control the position of the building component. For example, the assembly robot may move themagnetic fixture to change the position of the transferred building component from an initial position to the target position on the assembly table. This can enable further assembly to be performed without requiring position offsets to account for the actual position of the transferred building component on the assembly table. In this manner, the disclosed systems, methods and device can enable automated registry and an accurate datum to be formed for the transferred building component.

[0099] Furthermore, in some instances, the transferred building component may not include any suitable structures for an assembly robot to grip (e.g., for picking up and / or moving the building component). In some embodiments, the disclosed magnetic fixture includes a gripping member having a suitable design for gripping by the assembly robot. This can enable the assembly robot to use the magnetic fixture to move building components that may otherwise be unsuitable for automated handling by assembly robots.

[0100] The disclosed systems, methods, and devices for magnetic fixturing may be used in combination with any of the methods, systems and devices for automated assembly of building structures described in U.S. Patent Publication No. 2024 / 0017408 A1 , the entire contents of which are herein incorporated by reference.

[0101] Reference is now made to FIGS. 1A and 1 B. FIG. 1 A is a front perspective schematic diagram of a magnetic fixture 100a to support building components during automated assembly. FIG. 1 B is a rear perspective schematic diagram of the magnetic fixture 100a. Magnetic fixture 100a includes a magnet 104 and a fixture frame 108 attached to magnet 104.

[0102] Magnetic fixture 100a may be magnetically attached to a suitable assembly table (e.g., a steel assembly table) to support building components during assembly. The assembly table may be used in any suitable configuration. In some embodiments, the assembly table may be in a horizontal orientation and the magnetic fixtures support the building components on the horizontal assembly table during the assembly process. In other embodiments, the assembly table may be in other orientations including, for example, a vertical orientation or an oblique orientation.

[0103] Magnet 104 can be made of any suitably high-strength magnetic material that when magnetically attached to the assembly table provides sufficient rigidity and mechanical support to the building components. Magnet 104 may be toggleable between an ON state and an OFF state. In the ON state, magnet 104 becomes magnetic and can be attached to the assembly table. In the OFF state, magnet 104 becomes non-magnetic and cannot attach to the assembly table, and accordingly, can be removed from the assembly table.

[0104] In some embodiments, magnet 104 may be mechanically toggleable. For example, in the illustrated embodiment, magnet 104 can be mechanically toggleable using button 112. Button 112 may be pressed down to put magnet 104 in an ON state. Button 112 may be pulled upwards to put magnet 104 in an OFF state. In other embodiments, magnet 104 may be electronically toggleable (e.g., using an electromagnet, an electrical control signal, a wireless control signal).

[0105] In some embodiments, the magnetic fixture may include multiple magnets. Reference is now made to FIG. 1 C showing a front perspective schematic diagram of a magnetic fixture 100b to support building components during automated assembly. In the illustrated embodiment, magnetic fixture 100b includes a first magnet 104a, a second magnet 104b and a fixture frame 108. Multiple magnets may be used to provide a greater number of magnetic contact points with the assembly table. This may enable greater rigidity for fixture frame 108 to support, for example, longer building components. Each magnet 104a and 104b may include corresponding buttons 112a and 112b respectively to toggle the magnets between ON and OFF states. In other embodiments, the magnetic fixture may include a greater number of magnets (e.g., 3 to 6, > 6 etc.). A greater number of magnets may enable the magnetic fixture to support the building components with greater rigidity.

[0106] Fixture frame 108 can be the portion of the magnetic fixture that interacts / interfaces with the building components. Fixture frame 108 may include one or more frame surfaces to support the building components during the automated assembly. In the illustrated embodiment, fixture frame 108 of magnetic fixture 100b includes frame surfaces 116a-116c to support the building components.

[0107] Fixture frame 108 can be made using any suitable material that provides sufficient mechanical strength and rigidity for the specific application. The material may be selected based on the building components being supported and / or the building structure being assembled. For example, fixture frame 108 may be made using steel, aluminum, engineering plastic, and / or a combination thereof.

[0108] The shape and / or structure of fixture frame 108 may be tailored to meet the requirements of the specific application. For example, different shapes and / or structures may be used for fixture frame 108 for different applications including, for example, locating, clamping, providing horizontal support, providing vertical support, etc. for the building components. Using different shapes and / or structures of fixture frame 108 for identical magnets 104 can provide a high level of modularity for the disclosed magnetic fixtures, which can improve the flexibility of the disclosed systems, devices and methods and enable application in assembling a wide variety of building structures.

[0109] As a first example, reference is now made to FIG. 2 showing a perspective schematic diagram of a magnetic fixture 100c tailored to meet the requirements of an automated floor cassette assembly process. The floor cassette assembly includes a rimboard 204 and a floor joist 208. As shown in FIG. 2, the frame surfaces 116d and 116e of magnetic fixture 100c can define the location of a corner 212 of rimboard 204.

[0110] As a second example, reference is now made to FIG. 3 showing a perspective schematic diagram of a magnetic fixture 100d tailored to meet the requirements of supporting overhung subfloor sheathing panels 304. As shown in FIG. 3, the frame surface 116f of magnetic fixture 10Od can provide vertical support for overhung subfloor sheathing panels 304.

[0111] As a third example, reference is now made to FIG. 4 showing a top view schematic diagram of multiple magnetic fixtures 100e tailored to meet the requirements of an automated wall plate assembly process. As shown in FIG. 4, the frame surfaces 116g of magnetic fixtures 100e can locate and align wall plates and studs for extra-short wall panel 404. Reference is now made to FIG. 5 showing a perspective schematic diagram of the magnetic fixtures 100e in use with different building components. Asshown in FIG. 5, the frame surfaces 116g of magnetic fixtures 100e can locate and align wall plates and studs for the angled wall panel 504.

[0112] In some embodiments, the magnetic fixture may further include a gripping member. The gripping member can enable a robot to securely grip the magnetic fixture to move / manipulate the magnetic fixture. Reference is now made back to FIGS. 1A and 1 B. In the illustrated embodiment, magnetic fixture 100a includes a gripping member 120 positioned on fixture frame 108. Gripping member 120 may be positioned at any suitable position on fixture frame 108 or magnet 104 to enable a robot to grip magnetic fixture 100a with stability and rigidity.

[0113] Gripping member 120 may be made using any suitable material that provides sufficient mechanical strength and rigidity. In some embodiments, gripping member 120 may be a custom-machined block made of steel or aluminum.

[0114] Gripping member 120 may have any suitable design. In some embodiments, gripping member 120 may include one or more gripping surfaces for gripping by one or more gripper jaws of an assembly robot. Gripping member 120 may have any suitable number of gripping surfaces, for example, 1 to 6, greater than 6 etc. A larger number of gripping surfaces may provide a more rigid and / or secure connection. A small number of gripping surfaces may reduce the cost and / or complexity of the magnetic fixture.

[0115] For example, reference is now made to FIG. 6A showing a partial perspective schematic diagram of a magnetic fixture 100f having a gripping member 120a. Gripping member 120a includes two angled gripping surfaces 124a and 124b.

[0116] As another example, reference is now made to FIGS. 6B, 7 and 8. FIG. 6B is a partial perspective schematic diagram of a magnetic fixture 100g having a gripping member 120b. FIG. 7 is a partial front view schematic diagram of magnetic fixture 100g being gripped by gripper jaws 704a and 704b of a gripper 708 mounted to an assembly robot. FIG. 8 is another partial perspective schematic diagram of magnetic fixture 100g.

[0117] As shown in FIGS. 6B, 7 and 8, gripping member 120b of magnetic fixture 100g includes four angled gripping surfaces 124c, 124d, 124e and 124f. Duringmovement / manipulation of magnetic fixture 100g by the assembly robot, gripper jaws 704a and 704b can contact the four angled gripping surfaces 124c-124f to pull gripping member 120b towards a stopper block 712 of gripper 708 to provide a secure / rigid gripping connection.

[0118] In some embodiments, the gripping member may include one or more alignment surfaces for lateral centering / alignment during the gripping action by an assembly robot. For example, as shown in FIG. 8, gripping member 120b includes a first pair of angled lateral centering surfaces 128a and 128b on a first side 804. Gripping member 120b may further include a second pair of angled lateral centering surfaces (not shown in FIG. 8) on a second side 808. The lateral centering surfaces can enable gripper jaws 704 to repeatably form the gripping connection at the same position on the gripping member.

[0119] In some embodiments, the gripping member may be an extension of fixture frame 108. Reference is now made to FIG.1 D showing a front perspective schematic diagram of a magnetic fixture 100b to support building components during automated assembly, in accordance with another embodiment. In the example embodiment illustrated in FIG. 1 D, surface 116b of fixture frame 108 is designed to have a gripping member including angled surfaces 144 and 148 that are designed to complement a corresponding gripper of an assembly robot. In other embodiments, magnetic fixture 100a may not include a dedicated gripping member 120. For example, a robot may move / manipulate magnetic fixture 100a by directly gripping the fixture frame 108 and / or magnet 104.

[0120] In some embodiments, the magnetic fixture may further include a presence fixture or a presence sensor usable by an assembly robot to detect a presence and / or a position of the magnetic fixture. Reference is now made to FIGS. 9A and 9B showing schematic diagrams of gripper jaws 704a and 704b of a gripper 708 mounted to an assembly robot moved to a position to grip / pick up magnetic fixture 100h.

[0121] In the illustrated embodiment, magnetic fixture 100h includes a presence fixture. The presence fixture of magnetic fixture 100h may include a retroreflector 132.Gripper 708 may include a corresponding sensor 904 (e.g., a retroreflective optical sensor) to verify the presence and / or position of magnetic fixture 10Oh using retroreflector 132. Retroreflector 132 may be configured such that sensor 904 can only detect retroreflector 132 when the magnitude of the misalignment is sufficiently small to enable gripper jaws 704a and 704 to successfully grip the gripping member 120 (as shown in FIG. 9A). In the illustrated embodiment, the detection configuration of retroreflector 132 by sensor 904 may be adjusted by controlling size of through hole 136. A larger size of through hole 136 can allow a larger misalignment to be present while still enabling detection of retroreflector 132 by sensor 904.

[0122] FIG. 9B shows an example position where the magnitude of the misalignment is sufficiently large so that gripper jaws 704a and 704 cannot successfully grip the gripping member 120. As shown in FIG. 9B, in this position, the retroreflector 132 may not be detected by sensor 904 and the assembly robot may be configured to not attempt to grip / pick-up the magnetic fixture until the alignment is improved.

[0123] In some embodiments, magnetic fixture 100h may include a presence sensor (e.g., a retroreflective optical sensor) and gripper 708 may include a complementary presence fixture (e.g., a retroreflector).

[0124] In some embodiments, the magnetic fixture may not include a presence sensor. The assembly robot may use a different mechanism to detect a presence and / or a position of the magnetic fixture. For example, the gripper mounted to the assembly robot may include an imaging device configured to capture images of the magnetic fixture. A processor (e.g., a processor of a cloud server) may be used to execute a pose detection algorithm that detects a position of the magnetic fixture based on the captured images. The processor can compare the detected position with an expected position of the magnetic fixture. If the comparison indicates a sufficiently small misalignment, the gripper may attempt to grip / pick-up the magnetic fixture. If the comparison indicates a sufficiently large misalignment, a position of the gripper relative to the magnetic fixture may be adjusted before attempting to grip / pick-up the magnetic fixture.

[0125] In some embodiments, the disclosed system includes multiple magnetic fixtures and a robotic manipulator tool to move and manipulate the multiple magnetic fixtures. The robotic manipulator tool can be mounted to the distal end of an assembly robot. Reference is now made to FIG. 10 showing a perspective schematic diagram of a robotic manipulator tool 1004, in accordance with an embodiment.

[0126] In the illustrated embodiment, robotic manipulator tool 1004 includes a magnet actuator 1008, a tool changer 1012, a tool frame 1016, a gripper 708, and a sensor 904.

[0127] Tool frame 1016 can have any suitable design that provides sufficient rigidity and mechanical strength for mounting other components of robotic manipulator tool 1004. For example, tool frame 1016 may include a rigid aluminum frame that other components of robotic manipulator tool 1004 can be mounted to.

[0128] Tool changer 1012 can have any suitable design for automated connection of robotic manipulator tool 1004 with an assembly robot. Tool changer 1012 can enable automatic changing of the tool connected to the assembly robot based on the task to be performed by the assembly robot.

[0129] As described herein above with reference to FIGS. 7, 9A, and 9B, gripper 708 may include multiple gripper jaws 704. Gripper jaws 704 may be made using any suitable material that provides sufficient rigidity and mechanical strength for gripping the magnetic fixtures. For example, gripper jaws 704 may be made using steel or aluminum. Gripper 708 may further include an actuator connected to gripper jaws 704 to generate the gripping force for gripping the magnetic fixtures. The actuator may include, for example, a pneumatic or electric actuator.

[0130] Sensor 904 may include any suitable sensor. Sensor 904 may include, for example, a retroreflective optical sensor as described herein above with reference to FIGS. 9A and 9B.

[0131] Magnet actuator 1008 can have any suitable design to actuate the magnetic fixture. For example, the magnetic fixture may be mechanically toggleable using a button (e.g., button 112 shown in FIGS. 1A and 1 B). As illustrated in FIG. 10, magnet actuator1008 may include a button actuation arm. The button actuation arm may be made using any suitable material that provides sufficient rigidity and mechanical strength to actuate the button. For example, the button actuation arm may be made using aluminum. Reference is now additionally made to FIG. 11 showing a perspective schematic diagram of magnet actuator 1008 engaging with a button 112 of magnetic fixture 100a to push button 112 and toggle magnet 104 to an ON state.

[0132] In other embodiments, magnet actuator 1008 may have a different design. For example, magnet actuator 1008 may include a pneumatic cylinder that is extended to push button 112 and toggle magnet 104 to an ON state. As another example, the magnetic fixture may be electronically toggleable. Magnet actuator 1008 may include an electrical passthrough that can pass an ON / OFF electrical control signal to the electronically toggleable magnetic fixture.

[0133] In some embodiments, the robotic manipulator tool may include additional components for toggling the magnetic fixture from an ON state to an OFF state. As a first example, reference is now made to FIGS. 12A and 12B showing perspective schematic diagrams of a magnet actuator 1204 for toggling a button 112 of a magnet 104 from an ON state to an OFF state. Magnet actuator 1204 may include a pneumatic actuator 1208 and wedge jaws 1212a and 1212b. As shown in FIG. 12B, pneumatic actuator 1208 can drive wedge jaws 1212a and 1212b to impart a large vertical force on button 112 to toggle magnet 104 from an ON state to an OFF state.

[0134] As a second example, reference is now made to FIGS. 13A, 13B and 13C showing perspective schematic diagrams of a magnet actuator 1304 for toggling a button 112 of a magnet 104 from an ON state to an OFF state. Magnet actuator 1304 may include an actuator 1308 (e.g., a pneumatic actuator or an electric actuator) and customized prybar linkage 1312. As shown in FIGS. 13B and 13C, prybar linkage 1312 can engage with button 112 and actuator 1308 can generate a vertical force on button 112 via prybar linkage 1312 to toggle magnet 104 from an ON state to an OFF state.

[0135] In some embodiments, the robotic manipulator tool may include additional components for simultaneously moving / manipulating multiple magnetic fixtures. This can improve the cycle time for the assembly process.

[0136] In some embodiments, the disclosed system includes a storage unit to store the magnetic fixtures when they are not in use. Reference is now made to FIGS. 14A and 14B showing perspective schematic diagrams of a storage unit 1404. Storage unit 1404 may have any suitable design to support and store the magnetic fixtures 100 when not in use. In the illustrated embodiment, storage unit 1404 includes a large, vertical, steel weldment plate 1412 having an array of threaded holes 1416 (e.g., threaded holes 1416a, 1416b shown in FIG. 15) on it.

[0137] Storage unit 1404 may include multiple brackets 1408 (e.g., 1408a, 1408b, 1408c, etc.) attached to plate 1412 via threaded holes 1416. As shown in FIG. 14B, brackets 1408 can locate and hold magnetic fixtures 100 in position for storage. In some embodiments, storage unit 1404 may include brackets 1408 having different designs to support different designs of magnetic fixtures 100 (e.g., magnetic fixtures 100a-100e shown in FIGS. 1A-4).

[0138] The large number of threaded holes 1416 can enable a high level of modularity and flexibility for storage unit 1404. Threaded holes 1416 can support different configurations of brackets 1408 to easily change the number, position, and / or type of magnetic fixtures 100 that can be stored in storage unit 1404.

[0139] In some embodiments, each storage location in storage unit 1404 may include a storage sensor to detect the presence of a stored magnetic fixture at that location. Reference is now made to FIG. 15 showing a partial perspective schematic diagram of storage unit 1404 having storage sensors 1420a and 1420b. In the illustrated example, storage sensor 1420a may generate a storage sensor signal indicating the presence of a stored magnetic fixture at that storage location. Storage sensor 1420b may generate a storage sensor signal indicating the availability of that storage location for storing a magnetic fixture.

[0140] In some embodiments, multiple magnetic fixtures may be stacked at each storage location to increase the storage efficiency. For example, multiple identical magnetic fixtures may be stacked on top of each other. The assembly robot can pick up or drop off a magnetic fixture at the top of the stack.

[0141] In some embodiments, the fixture frame may be removably attached to the magnet. For example, the assembly robots may automatically detach the fixture frames from the magnets after use. The fixture frames and the magnets may then be stored separately. This may improve the storage efficiency of the magnetic fixtures.

[0142] Reference is now made to FIGS. 16A, 16B and 16C, which illustrate process flows for example methods 1600a, 1600b, and 1600c respectively of use of magnetic fixtures to support building components on an assembly table during automated assembly of a building structure. Example methods 1600a-1600c may also be collectively referred to as method 1600. The magnetic fixtures may be any suitable magnetic fixtures described herein above and concurrent reference is also made to FIGS. 1A to 15 showing different embodiments of the magnetic fixtures and the robotic manipulator tool.

[0143] Method 1600 may at least partially be performed by a system configured for automated assembly of building structures. Reference is now additionally made to FIG. 17 showing an example system 1704 for automated assembly of building structures. In the illustrated embodiment, system 1704 includes a user computer terminal 1708 connected, via network 1720, to one or more control server(s) 1716 (e.g., cloud servers) and a robotic assembly cell 1712. In other embodiments, system 1704 may include a different combination of components. For example, system 1704 may include multiple robotic assembly cells.

[0144] In operation, a user may interact with the user computer terminal 1708. The user computer terminal 1708 may, for example, enable the user to upload one or more design files 1724. The design files 1724 can correspond to model designs for assembling building structures using robotic assembly cell 1712 (e.g., wall panels, roof / ceiling structures, etc.).

[0145] The design file(s) 114 may be transmitted from the user computer terminal 1708 to the server 1716, via network 1720. Server 1716 may receive, parse and analyze the design file. In turn, the server 1716 may generate control instructions for assembling the corresponding building structure(s). The control instructions are then transmitted to the robotic assembly cell 1712 for automated assembly (e.g., in real-time or near realtime). In some example cases, the server 1716 may host one or more Al algorithms / models, which provide enhanced functionality in determining and generating optimal assembly control instructions.

[0146] Server 1716 may serve as an intermediary between user computer terminal 1708 and the robotic assembly cell 1712. More particularly, a user may deploy the robotic assembly cell 1712 at any desired on-site or off-site location, and further connect (e.g., plug-in) the user computer terminal 1708 and robotic assembly cell 1712 to network 1720. Server 1716 may then provide a “ready-to-use” software platform for remotely controlling and monitoring operation of the robotic assembly cell 1712.

[0147] In more detail, user computer terminal 1708 may be a desktop or laptop computer, but may also refer to a smartphone, tablet computer, as well as a wide variety of “smart” devices capable of data communication. The user computer terminal 1708 can include a display for presenting a graphical user interface (GUI). The GUI may allow the user to input various building structure design files (e.g., CAD models).

[0148] Server 1716 can be a computer server that is connected to network 1720. Server 1716 may include a processor, volatile and non-volatile memory, at least one network interface, and may have various other input / output devices. To this end, server 1716 need not be a dedicated physical computer. For example, in various embodiments, the various logical components provided on server 1716 may be hosted by a third party “cloud” hosting service such as Amazon™ Web Services™ Elastic Compute Cloud (Amazon EC2). Additionally, as with all devices shown in system 1704, there may be multiple servers 1716, although not all are shown. It will be understood that reference to a server 1716, in the singular, may refer to one or more servers.

[0149] Server 1716 can provide cloud-based motion planning and control for the robotic assembly cell 1712. Server 1716 may also provide more general production management services for the robotic cell, including: (i) assembly planning and scheduling, (ii) real-time or near real-time monitoring of assembly progress, (iii) management of inventory at the robotic cell, (iv) assembly and production cost estimation, (v) controlling and supervision of required maintenance, (vi) analytics and report generation, (vii) logistics and shipping management, and / or (viii) building and component model analysis and optimization.

[0150] In some examples, some or all of the processes provided by the server 1716 can be performed by one or more Al algorithms / models, hosted on the server 1716. For example, this includes the cloud-based motion and path planning, as well as the various general production management services.

[0151] Network 1720 may be connected to the internet. Typically, the connection between network 1720 and the Internet may be made via a firewall server (not shown). In some cases, there may be multiple links or firewalls, or both, between network 1720 and the Internet. Some organizations may operate multiple networks 1720 or virtual networks 1720, which can be internetworked or isolated. These have been omitted for ease of illustration, however it will be understood that the teachings herein can be applied to such systems. Network 1720 may be constructed from one or more computer network technologies, such as IEEE 802.3 (Ethernet), IEEE 802.11 and similar technologies.

[0152] Reference is now additionally made to FIG. 18 showing a schematic diagram of an example robotic assembly cell 1712. As shown, the robotic assembly cell 1712 may include one or more assembly robots 1804a - 1804c used for assembling various building structures (e.g., wall panels, ceilings / roofs, floor panels, staircases, etc.). The assembly robots 1804 can include any suitable robotic system including, by way of example, robotic arms and / or robotic gantry systems. The assembly robots 1804 can be stationary, or may dynamically move around the robotic assembly cell 1712 (e.g., along slidable tracks 1808). Operation of assembly robots 1804 may be controlled, and guided by control instructions received from server 1716. In other cases, one or more assemblyrobots 1804 may be controlled by a local computing system or processor of the robotic assembly cell 1712.

[0153] Robotic assembly cell 1712 may be flexibly configured or re-configured (e.g., re-programmed) to perform different or multiple tasks. For example, multi-functional assembly robots 1804 can be re-configured to assemble different building structures, on as-need basis (or otherwise assemble different portions of the same structure). This can be done by transmitting new or updated control instructions to the robotic assembly cell 1712. Accordingly, the same robotic assembly cell 1712 can act as a one-stop integrated solution for various assembly needs. This, in turn, minimizes the amount of system resources and footprint required to assemble building units having different types of constituent building structures.

[0154] Robotic assembly cell 1712 may also include an assembly table 1812 for positioning building components for assembly. The robotic assembly cell 1712 may also include other system components (e.g., cutting tables, storage units for magnetic fixtures, etc.) that may be used in automated or manual assembly.

[0155] Robotic assembly cell 1712 can be used to pre-fabricate (or pre-assemble) building structures, which may be transported or shipped to a construction site for rapid assembly (e.g., into a housing unit). In other examples, the robotic assembly cell 1712 may itself be portable, such that it may be shipped directly to a construction site.

[0156] At act 1604, method 1600 may include analyzing the assembly data associated with the building structure to determine a magnetic fixture arrangement. For example, server 1716 can analyze the assembly data associated with the building structure to determine a magnetic fixture arrangement to support the building components during automated assembly of the building structure. The assembly data may be included, for example, in one or more design files 1724 received from user computer terminal 1708. The determined magnetic fixture arrangement may include at least one of a number, a type, an assembly table position, an assembly table orientation, and a sequence of positioning and removal of the magnetic fixtures. The sequence of positioning and removal of the magnetic fixtures may be defined in relation to the sequence of positioningand assembly of the building components. The sequence may include, for example, positioning a first portion of the building components, positioning a first portion of the magnetic fixtures, positioning a second portion of the building components, positioning a second portion of the magnetic fixtures, assembling a first portion of the building structure, removal of the magnetic fixtures, assembling the remaining portion of the building structure.

[0157] As a first example, a magnetic fixture arrangement may be determined to support overhanging sheathing. When subfloor sheets are placed, they may require to be cut in one or more locations. If the offcut area is excessively large, it could pose one or more problems. First, the sheet may fall off or slide away (at least by a small amount) from its expected position due to the weight of the overhanging piece before being fastened to the underlying building components. Second, even if the sheet is accurately fastened, it may bend due to the overhanging weight. This bending may cause inaccurate cutting in the subsequent robotic steps.

[0158] Reference is now made to FIG. 19 showing a schematic diagram of an example of a significantly large overhanging subfloor section 1904, where lines 1908 and 1912 mark the cut lines. For such overhanging sheets, some vertical supports may be required to maintain the subfloor in its correct position until it is nailed to the underlying joists and the redundant area is cut accurately. Support may be provided at a center of gravity position of the overhanging section using a magnetic fixture.

[0159] This can be necessary to prevent potential collisions between the falling cutout section and components of the assembly robots. In some embodiments, a modified cutting method may be used. For example, instead of executing a complete cut of the subfloor component, small uncut segments may be intentionally left along the cutline. These residual connections can help retain the cut-out piece in place, thereby preventing unintended displacement or collision until manual removal is subsequently performed.

[0160] Reference is now additionally made to FIG. 20. FIG. 20 shows a schematic diagram of an example overhanging subfloor section 2004 and corresponding cut line 2008. Overhanging subfloor section 2004 may be small and adequately supportedvertically so that no fixtures may be required to support overhanging subfloor section 2004.

[0161] To determine when fixture placement is required, a configurable parameter called “min_overhung_area” may be defined denoting the minimum overhanging area that requires additional vertical support. For each sheet requiring cuts, server 1716 may compare its overhanging area against the “min_overhung_area” parameter. Server 1716 may determine magnetic fixtures to be added to the magnetic fixture arrangement in response to the overhanging area being larger than “min_overhung_area” parameter.

[0162] If a sheet requires the magnetic fixtures to be added, server 1716 may determine the total number of magnetic fixtures to be added using another configurable parameter called “standard_overhung_area” that represents the area that each magnetic fixture can support. Accordingly, server 1716 can determine the total number of magnetic fixtures to be added to the magnetic fixture arraignment to support the overhanging sheathing using the following equation: fixtures = [ overhanging area 1

[0163] A uniform mass density may be assumed for the subfloor and the overhanging area may be split into equal smaller rectangles. Server 1716 may determine the magnetic fixture arrangement with a magnetic fixture positioned at the center of each rectangle. During this process, the overhanging area may be assumed to be fully rectangular. However, if the overhanging area is concave or not fully rectangular (for example, as illustrated in FIG. 20), server 1716 may split the total overhanging area into multiple rectangles and repeat the process for each rectangle.

[0164] An advantage provided by making the “standard_overhung_area” configurable is that many different types of sheathing materials may be used with varying thickness or density. The “standard_overhung_area” parameter can be separately set for each material type. The different values of the parameters may be stored, for example, in a memory of server 1716.

[0165] Reference is now made to FIG. 21 showing a schematic diagram of example floor cassettes incorporating a cut line 2104 and a plumbing hole 2108. Because the sheet-supporting magnetic fixtures may be taller compared with other types of fixtures, server 1716 may position the magnetic fixtures using a clearance distance to avoid collisions between the magnetic fixtures and the cutting tools (e.g., a saw, a router, etc.) mounted to the assembly robots.

[0166] After determining the magnetic fixtures to be added to the magnetic fixture arrangement, server 1716 may generate robotic control instructions for positioning the magnetic fixtures in the determined magnetic fixture arrangement. In some examples, the magnetic fixtures may be positioned immediately before placing that subfloor. In some examples, all the magnetic fixtures in the magnetic fixture arrangement may be positioned before placement of any sheathing parts.

[0167] As a second example, server 1716 may determine a magnetic fixture arrangement to provide stability support for joists. Joists are typically long parts that usually span the entire length of a floor cassette. The joists may vary in thickness and type based on their structural role. Ideally, the joists should be perfectly straight along their length axis, but in practice, they often exhibit a slight outward bend. This deviation can cause complications when the joists are being fastened to the upper sheets and may incur inaccuracies during the framing process. In addition, these components may become unstable and risk toppling to their sides after being placed on the assembly table.

[0168] To mitigate both bending and toppling issues and ensure that the joists are straightened and secured in their positions, server 1716 may determine pairs of magnetic fixtures to be strategically placed along the length axis on both sides of each joist. Reference is now made to FIG. 22 showing a schematic diagram of an example joist 2204 supported by multiple magnetic fixtures 100m, 100n, 100o and 100p positioned on a first side of joist 2204 and multiple magnetic fixtures 100q, 10Or, 100s and 10Ot positioned on the opposite side of joist 2204. The magnetic fixtures 100m-1 OOt may be positioned by the assembly robots using force-torque sensor-guided motion to ensure that the joists are firmly held from both sides and maintained in their proper positions.

[0169] Server 1716 may define a parameter called “joist_fixtures_distance” to determine the location and number of magnetic fixtures required to support each joist. The “joist_fixtures_distance” parameter may denote the maximum allowable spacing between two consecutive fixtures along a joist. Assuming that a pair of magnetic fixtures is added to each end of the joist, the total number of required magnetic fixtures needed can be calculated using the following equation:Q length of joist- length of fixture]— — r— - - - + 1 ... (2) joist_fixtures_distance I /

[0170] After determining the total number of magnetic fixtures, server 1716 may determine the final spacing between the fixtures. This can enable server 1716 to precisely determine the location for each magnetic fixture based on the dimensions of the joist and the determined spacing.

[0171] Server 1716 may use any one of at least two sequencing strategies for positioning the magnetic fixtures. First, both rows of magnetic fixtures may be positioned along the joist after the joist is placed. Second, a first row of magnetic fixtures may be positioned, followed by placement of the joist and wherein the joist is datum to the first row of magnetic fixtures using a force-torque sensor-guided motion. Subsequently, the second row of magnetic fixtures may be positioned, for example, using identical sensor- guided motion.

[0172] As a third example, server 1716 may determine a magnetic fixture arrangement to provide support for floor cassette datum ing. Datum ing refers to the process of establishing a reference point or plane for measurement or positioning. Unlike wall panels which are typically fully rectangular, floor cassettes and other prefabricated building components can be modelled in various, often non-rectangular shapes. To properly datum the cassette or clamp the parts together, it may be required to add magnetic fixtures to the components along the perimeter of the cassette. These parts usually include exterior joists and rim boards. Refence is now made to FIG. 23 showing a schematic diagram of an example magnetic fixture arrangement of multiple magnetic fixtures 100 around the perimeter of a floor cassette 2304.

[0173] It may be required to position the magnetic fixtures to prevent obstruction of any framing operations, for example, subsequent fastening actions. To prevent such obstructions, a configurable parameter may be defined representing the minimum distance between the magnetic fixtures and any nailing area. If the magnetic fixtures cannot fit within the minimum distance, they may be rotated by 90 degrees. The orientation of the magnetic fixtures may not always need to align with the length axis of the part they support and the orientation may be adjusted in response to the magnetic fixture not fitting within the minimum distance. In the example illustrated in FIG. 23, the magnetic fixtures 100i, 10Oj, 100k and 1001 may be reoriented to meet the minimum distance requirements.

[0174] Adding magnetic fixtures to at least a pair of perpendicular edges along the perimeter of the cassette may be essential to create a datuming corner. However, it may be beneficial to place magnetic fixtures along all edges of the cassette’s perimeter, i.e. , along all the perimeter parts. In some embodiments, server 1716 may utilize this conservative method in determining magnetic fixture arrangements. Additionally, each perimeter part may require at least two magnetic fixtures, one at each end. However, if the two parts share one end and form a concave corner on the perimeter, it may suffice to only use one rectangular magnetic fixture on that corner.

[0175] While each perimeter part may generally require at least two magnetic fixtures on its two ends, longer parts may require greater number of magnetic fixtures to provide increased stability. Server 1716 may use another configurable parameter called “perimeter_fixtures_distance” that specifies the maximum distance between two consecutive magnetic fixtures along a part on the perimeter of the cassette. Based on the shape of the floor cassette, there may be more than four parts around the perimeter. Reference is now made to FIG. 24 showing a schematic diagram of an example floor cassette 2404 that has seven parts 2408-2432 around its perimeter. The number of required fixtures can be calculated based on the maximum spacing, the length of the perimeter parts, and the number of concave corners along the perimeter, using the following equation:v-1 / length of part\#fixtures = > —:— - — — - -r- - + 1Z_i \ penmeter_fixtures_distance I perimeter part ' '- #concave corners along the perimeter

[0176] As described previously, the joists around the exterior may also require another set of magnetic fixtures for stability. In some cases, a single set of magnetic fixtures may suffice for both joist stability and perimeter stability. However, if the initial set supporting the joist stability does not meet the perimeter requirements, a second set of magnetic fixtures may be required to provide adequate perimeter support. When adding two sets of magnetic fixtures, server 1716 may implement collision checking procedures to avoid collisions or scenarios where two magnetic fixtures are too close to each other. In some embodiments, server 1716 may define an additional configurable parameter to control the minimum distance between any two magnetic fixtures to control such edge cases.

[0177] Server 1716 may include the placement action of the perimeter magnetic fixtures in the robotic control instructions sequence before including the placement actions of the perimeter parts to ensure proper datuming from the beginning of the robotic assembly process.

[0178] As a fourth example, server 1716 may determine a magnetic fixture arrangement to provide support for framing floor cassettes. The magnetic fixtures can be crucial in the framing process, particularly when assembling joists and rim boards. In many cases, one side of a component may be open, and nailing from one side could cause the component to shift to the opposite side. Reference is now made to FIG. 25 showing a schematic diagram of an example scenario, where a joist 2504 is open-ended on one side 2508, but is required to be nailed to rim boards on the other side 2512. In such situations, to prevent any deflection of the part, server 1716 may determine the magnetic fixture arrangement to securely position a magnetic fixture 100 on the open- ended side 2508 of the joist 2504 to keep it intact during nailing.

[0179] Server 1716 may generate the robotic control instructions to position the magnetic fixtures on the open side of a component either before or after the part is placed,depending on the sequence of actions and the chosen robot maneuver. This placement may be achieved through force-torque sensor-guided motion. Regardless of the order of positioning the magnetic fixtures relative to the part placement, server 1716 may ensure that the magnetic fixtures are positioned before the part is fastened to any adjoining parts.

[0180] In some edge cases, a part may not be open from either side in the modelling, but in the assembly process, may require a magnetic fixture on one side before it is fastened on the other side. Once supported, the magnetic fixture could be removed to allow the part to be fastened on the other side as well. In some other edge cases, a part may be open-ended on both sides. In such cases, server 1716 may only add a magnetic fixture on one side of the part to ensure that the part will be maintained in its expected position.

[0181] Referring now to FIG. 16A, at act 1608, method 1600 may include positioning the magnetic fixtures on the assembly table based on the determined magnetic fixture arrangement. Server 1716 may generate one or more robot control instructions for execution by one or more assembly robots 1804 of robotic assembly cell 1712.

[0182] Assembly robots 1804 may execute the robotic control instructions to mount a robotic manipulator tool (e.g., robotic manipulator tool 1004 shown in FIG. 10) to at least one of assembly robots 1804. The robotic manipulator tool can enable the assembly robot to grip and retrieve one or more magnetic fixtures based on the determined magnetic fixture arrangement. The magnetic fixtures may be retrieved, for example, from a storage unit (e.g., storage unit 1404 shown in FIGS. 14A and 14B).

[0183] Assembly robots 1804 may further execute the robotic control instructions to position the magnetic fixtures on the assembly table based on the determined magnetic fixture arrangement. In some embodiments, assembly robot 1804 may include a forcetorque sensor and the force-torque feedback is used to detect when the magnetic fixture contacts the surface of the assembly table.

[0184] After placement, assembly robots 1804 may toggle the magnetic fixtures from an OFF state to an ON state to attach the magnetic fixtures at the correspondingpositions on the assembly table. Assembly robot 1804 may use a magnet actuator (e.g., magnet actuator 1008 shown in FIGS. 10 and 11 ) to toggle the magnetic fixtures to the ON state.

[0185] At act 1612, method 1600 may include positioning the building components on the assembly table using the magnetic fixtures to support the building components. Assembly robots 1804 may execute the robotic control instructions to change a tool mounted to the assembly robot. For example, the tool may be changed to a tool designed to pick-up and position the building components. Assembly robots may further execute the robotic control instructions to position the building components at target positions based on the building structure being assembled.

[0186] In some embodiments, at least a portion of the building components may be positioned on the assembly table before positioning any of the magnetic fixtures on the assembly table. For example, with reference to method 1600b shown in FIG. 16B, at act 1606, assembly robots 1804 may execute the robotic control instructions to position at least a portion of the building components on the assembly table before positioning any of the magnetic fixtures on the assembly table. At act 1608, assembly robots 1804 may execute the robotic control instructions to position the magnetic fixtures on the assembly table. In some cases, the position of the magnetic fixtures may be defined with reference to the building components positioned at act 1606. At act 1610, assembly robots 1804 may execute the robotic control instructions to position the remaining portion of the building components on the assembly table.

[0187] In some embodiments, assembly robots 1804 may switch multiple times between positioning the magnetic fixtures and the building components. For example, as shown in FIGS. 16A and 16B, method 1600 may recursively loop through any suitable combination of acts (e.g., acts 1608 and 1612 shown in FIG. 16A, acts 1608 and 1610 shown in FIG. 16B) until all the magnetic fixtures and all the building components are positioned on the assembly table.

[0188] At act 1616, method 1600 may include assembling the building components to form the building structure. For example, the building components supported in positionby the magnetic fixtures may be fastened / connected together to form the desired building structure.

[0189] In some embodiments, assembly robots 1804 may assemble a first portion of the building structure using the positioned magnetic fixtures to support the corresponding building components. Subsequently, assembly robots 1804 may move the magnetic fixtures to new positions and assemble a second portion of the building structure. For example, as shown in FIGS. 16A and 16B, method 1600 may recursively loop through any suitable combination of acts (e.g., acts 1608, 1612, and 1616 shown in FIG. 16A, acts 1608, 1610 and 1616 shown in FIG. 16B) until the entire building structure is assembled.

[0190] At act 1620, method 1600 may include removing the magnetic fixtures from the assembly table. Assembly robots 1804 may execute the robotic control instructions to mount a robotic manipulator tool to at least one of assembly robots 1804. The robotic manipulator tool may include a magnet actuator (e.g., magnet actuator 1204 shown in FIGS. 12A and 12B, magnet actuator 1304 shown in FIGS. 13A-13C) designed to toggle the magnetic fixtures from an ON state to an OFF state. The magnetic fixtures may be removed from the assembly table after being toggled to the OFF state.

[0191] In some embodiments, at least a portion of the building structure may be assembled after removing the magnetic fixtures from the assembly table. For example, with reference to method 1600c shown in FIG. 16C, at act 1618, assembly robots 1804 may execute the robotic control instructions to assembly at least a portion of the building structure while the building components are supported by the magnetic fixtures. The magnetic fixtures may not be required to support the building components during assembly of the remaining portion of the building structure. Accordingly, at act 1620, assembly robots 1804 may execute the robotic control instructions to remove the magnetic fixtures from the assembly table. At act 1622, assembly robots 1804 may execute the robotic control instructions to assembly the remaining portion of the building structure.

[0192] In some embodiments, assembly robots 1804 may further execute the robotic control instructions to move the magnetic fixtures from the assembly table to a different location (e.g., storage unit 1404 shown in FIGS. 14A and 14B). The robotic manipulator tool mounted to the assembly robots 1804 may include a gripper (e.g., gripper 708 shown in FIG. 7) to grip and move the magnetic fixtures. In some embodiments, the robotic manipulator tool may include a sensor (e.g., sensor 904 shown in FIGS. 9A and 9B) to verify that the magnetic fixture is present in the expected position before engaging with and removing the magnetic fixture from the assembly table.

[0193] Reference is now made to FIG. 26 showing a front perspective schematic diagram of a magnetic fixture 100u, in accordance with an embodiment. Magnetic fixture 100u includes a magnet 104 and a fixture frame 110 coupled to magnet 104. Magnetic fixture 100u may be used to position a building component on an assembly surface during automated assembly by an assembly robot.

[0194] Fixture frame 110 may be made using any suitable material that provides sufficient mechanical strength and rigidity for the specific application. The material may be selected based on the building structure being assembled. For example, fixture frame 110 may be made using steel, aluminum, engineering plastic, and / or a combination thereof.

[0195] In some embodiments, fixture frame 110 may be removably coupled to magnet 104. For example, an assembly robot may automatically decouple fixture frame 110 from magnet 104 after use. Fixture frame 110 and magnet 104 may then be stored separately. This can improve the storage efficiency of magnetic fixture 10Ou when it is not in use.

[0196] In the illustrated embodiment, fixture frame 110 includes a coupling member 118 and a gripping member 120. Coupling member 118 may have any suitable position on fixture frame 110. In the illustrated embodiment, coupling member 118 is located at an end of fixture frame 110. In other embodiments, coupling member 118 may be positioned differently.

[0197] Coupling member 118 may have any suitable design to form a sufficiently rigid and detachable connection with a positioning assembly. The positioning assembly can be attached to a building component so that an assembly robot can move magnetic fixture 100u, while being connected to the positioning assembly, to reposition the building component.

[0198] In the illustrated embodiment, coupling member 118 is formed as a coupling pin that mates with a suitably sized opening in the positioning assembly to form the detachable connection with the positioning assembly. In other embodiments, coupling member 118 may have any other suitable design, for example, any design that forms a suitably rigid and detachable male-female-type connection with a corresponding component of the positioning assembly.

[0199] Coupling member 118 may be made of any suitable material that provides sufficient mechanical strength and rigidity to form the connection with the positioning assembly and enable movement of the building component via the connection. In some embodiments, coupling member 118 may be formed using a hardened steel material. In other embodiments, a different material may be used to form coupling member 118.

[0200] Gripping member 120 may have any suitable design and position on fixture frame 110 to enable an assembly robot to securely grip magnetic fixture 100u for picking up or moving the magnetic fixture. In the illustrated embodiment, gripping member 120 is positioned at an opposing end from coupling member 118. In other embodiments, gripping member 120 may be positioned differently. For example, gripping member 120 may be centrally positioned on fixture frame 110.

[0201] Gripping member 120 may be made using any suitable material that provides sufficient mechanical strength and rigidity. In some embodiments, gripping member 120 may be a custom-machined block made of steel or aluminum.

[0202] In some embodiments, fixture frame 110 may not include a gripping member 120. For example, magnet 104 may instead have a gripping member usable by the assembly robot for gripping magnetic fixture 100u.

[0203] In some embodiments, gripping member 120 may include one or more gripping surfaces for gripping by one or more gripper jaws of an assembly robot. Gripping member 120 may have any suitable number of gripping surfaces, for example, 1 to 6, greater than 6 etc. A larger number of gripping surfaces may enable an assembly robot to grip magnetic fixture 10Ou with greater stability. A smaller number of gripping surfaces may reduce the cost and / or complexity of magnetic fixture 100u and / or corresponding gripper for the assembly robot.

[0204] In some embodiments, gripping member 120 may include two angled gripping surfaces 124a and 124b (FIG. 6A). As another example, gripping member 120 may include four angled gripping surfaces 124c, 124d, 124e and 124f (FIGS. 6B and 7). In some embodiments, gripping member 120 may include one or more alignment surfaces for lateral centering / alignment during the gripping action by an assembly robot. For example, gripping member 120 may include a first pair of angled lateral centering surfaces 128a and 128b on a first side 804, and a second pair of angled lateral centering surfaces on a second side 808 (FIG. 8). The lateral centering surfaces can enable the assembly robot to reproducibly form the gripping connection at the same position on gripping member 120.

[0205] Magnet 104 can be made of any suitably high-strength magnetic material that when magnetically attached to an assembly surface (e.g., a steel assembly table) provides sufficient rigidity and mechanical support to maintain a position of a building component (that is coupled to magnetic fixture 100u via a positioning assembly). Magnet 104 may be toggleable between an ON state and an OFF state. In the ON state, magnet 104 becomes magnetic and the corresponding magnetic force fixes magnet 104 to the assembly surface. In the OFF state, magnet 104 becomes non-magnetic and the corresponding magnetic force is removed so that magnet 104 / magnetic fixture 100u can be moved to another position on the assembly surface or removed away from the assembly surface.

[0206] In some embodiments, magnet 104 may be mechanically toggleable. For example, in the illustrated embodiment, magnet 104 can be mechanically toggleable using button 112. Button 112 may be pressed down to put magnet 104 in an ON state.Button 112 may be pulled upwards to put magnet 104 in an OFF state. In other embodiments, magnet 104 may be electronically toggleable (e.g., using an electromagnet, an electrical control signal, a wireless control signal).

[0207] During automated assembly, magnet 104 may initially be in an OFF state. An assembly robot can use magnetic fixture 100u, while being coupled to a building component via a positioning assembly, to move the coupled building component to a target position. After the coupled building component reaches the target position, magnet 104 may be toggled to an ON state to fix the position of magnetic fixture 10Ou and thereby the position of the coupled building component. The assembly robot can then perform further assembly actions related to the coupled building component while the magnetic fixture 100u maintains the position of the coupled building component.

[0208] In some embodiments, magnetic fixture 100u may further include a presence fixture or a presence sensor usable by an assembly robot to detect a presence and / or a position of the magnetic fixture. For example, magnetic fixture 100u may include a retroreflector 132 (FIGS. 9A and 9B). The assembly robot may include a corresponding sensor 904 to verify the presence and / or position of magnetic fixture 100u using retroreflector 132. Retroreflector 132 may be configured such that sensor 904 can only detect retroreflector 132 when the magnitude of a misalignment is sufficiently small to enable gripper jaws 704a and 704b of the assembly robot to successfully grip the gripping member 120 (as shown in FIG. 9A). FIG. 9B shows an example position where the magnitude of the misalignment is sufficiently large so that gripper jaws 704a and 704 cannot successfully grip the gripping member 120. As shown in FIG. 9B, in this position, the retroreflector 132 may not be detected by sensor 904 and the assembly robot may be configured to not attempt to grip / pick-up the magnetic fixture until the alignment is improved.

[0209] In some embodiments, the position of the presence sensor and the presence fixture may be interchanged between the magnetic fixture and the assembly robot. For example, magnetic fixture 100u may include a presence sensor (e.g., a retroreflective optical sensor) and the assembly robot may include a complementary presence fixture (e.g., a retroreflector).

[0210] In some embodiments, magnetic fixture 100u may not include a presence fixture or a presence sensor. The assembly robot may use a different mechanism to detect a presence and / or a position of magnetic fixture 100u. For example, the gripper mounted to the assembly robot may include an imaging device configured to capture images of magnetic fixture 100u. A processor (e.g., a processor of a cloud server) may be configured to execute an object detection algorithm that detects a presence of magnetic fixture 100u based on captured images. In some embodiments, a processor may be configured to execute a pose estimation algorithm that detects a position (e.g., a location and an orientation) of magnetic fixture 100u based on the captured images. The processor can compare the detected position with an expected position of magnetic fixture 100u. If the comparison indicates a sufficiently small misalignment, the gripper may attempt to grip / pick-up magnetic fixture 100u. If the comparison indicates a sufficiently large misalignment, a position of the gripper relative to magnetic fixture 100u may be changed before attempting to grip / pick-up magnetic fixture 100u.

[0211] Reference is now made to FIGS. 27A-29B. FIG. 27A shows a perspective schematic diagram of positioning assembly 300a, in accordance with an embodiment. FIG. 27B shows a perspective schematic diagram of positioning assembly 300a attached to a building component 2704 on an assembly surface 2716. FIG. 28A shows a perspective schematic diagram of positioning assembly 300b, in accordance with an embodiment. FIG. 28B shows a perspective schematic diagram of positioning assembly 300b attached to a building component 2804 on an assembly surface 2816. FIG. 29A shows a perspective schematic diagram of positioning assembly 300c, in accordance with an embodiment. FIG. 29B shows a perspective schematic diagram of positioning assembly 300c attached to a building component 2904 on an assembly surface 2916. Positioning assembly 300 can be used to position a building component on an assembly surface during automated assembly by an assembly robot.

[0212] Positioning assembly 300 includes an assembly frame 306 and a fixture coupler 308. Positioning assembly 300 may use any suitable mechanism to couple fixture coupler 308 with assembly frame 306. In some embodiments, assembly frame 306 and fixture coupler 308 may have multiple openings for fasteners to rigidly couple fixturecoupler 308 with assembly frame 306. In other embodiments, a different coupling mechanism may be used.

[0213] Assembly frame 306 and fixture coupler 308 may be made using any suitable material that provides sufficient mechanical strength and rigidity for the specific application. The material may be selected based on the specific application that positioning assembly 300 is used for. For example, the material may be selected to be robust enough to withstand the normal wear-and-tear of an industrial production tool. For a specific application of floor cassette assembly, the material may be selected so that positioning assembly 300 has sufficient mechanical strength and rigidity to enable an assembly robot to impart up to 1000N of force through the positioning assembly and into the floor cassette structure. In some embodiments, assembly frame 306 and fixture coupler 308 may be made using steel. In other embodiments, a different material may be used (e.g., aluminum, alloy steel, etc.).

[0214] Fixture coupler 308 may have different structural designs based on the type and / or structure of the building component that the positioning assembly will be attached to. For example, FIGS. 27A, 28A and 29A show three fixture coupler structural designs for positioning assembly 300a, 300b, and 300c respectively.

[0215] Fixture coupler 308 may have any suitable component to form a detachable connection with a magnetic fixture (e.g., magnetic fixture 100u shown in FIG. 26). coupling pin. In the illustrated embodiment, fixture coupler 308 includes an opening 316 that is sized and shaped to receive a coupling pin of a magnetic fixture (e.g., coupling member 118 shown in FIG. 26) to form the detachable connection. In some embodiments, the portion of fixture coupler 308 that defines opening 316 may be formed using a hardened metal (e.g., hard anodized aluminum or hardened steel) to prevent wear during attachment and detachment occurrences between fixture coupler 308 and the magnetic fixture. In other embodiments, fixture coupler 308 may have any other suitably designed component that forms a rigid and detachable connection with a corresponding component of the magnetic fixture.

[0216] Assembly frame 306 may have any suitable structure to enable a sufficiently rigid attachment to the building component. Assembly frame 306 may have different structural designs based on the type and / or structure of the building component that the positioning assembly will be attached to. For example, FIGS. 27A, 28A and 29A show three assembly frame structural designs for positioning assembly 300a, 300b, and 300c respectively.

[0217] Assembly frame 306a of FIG. 27A includes a first frame arm 320a and a second frame arm 320b that is substantially perpendicular to first frame arm 320a. In this context, substantially perpendicular defines an angle that is within ±0.5°. Fixture coupler 308a may be coupled to an outer portion of the substantially perpendicular joint formed by first frame arm 320a and second frame arm 320b.

[0218] FIG. 27B illustrates positioning assembly 300a attached to an exterior corner 2712 formed by sides 2708a and 2708b of building component 2704. First frame arm 320a of positioning assembly 300a abuts against side 2708a of building component 2704. Second frame arm 320b of positioning assembly 300a abuts against side 2708b of building component 2704. First frame arm 320a and second frame arm 320b can enable an assembly robot to apply forces to control a position of exterior corner 2712 on an assembly surface.

[0219] Assembly frame 306b of FIG. 28A includes a first frame arm 320a and a second frame arm 320b that is substantially perpendicular to first frame arm 320a. In this context, substantially perpendicular defines an angle that is within ±2% of 90°. Fixture coupler 308b may be coupled to an inner portion of the substantially perpendicular joint formed by first frame arm 320a and second frame arm 320b.

[0220] FIG. 28B illustrates positioning assembly 300b attached to an interior corner 2812 formed by sides 2808a and 2808b of building component 2804. First frame arm 320a of positioning assembly 300b abuts against side 2808a of building component 2804. Second frame arm 320b of positioning assembly 300b abuts against side 2808b of building component 2804. First frame arm 320a and second frame arm 320b can enablean assembly robot to apply forces to control a position of interior corner 2812 on an assembly surface.

[0221] Assembly frame 306c of FIG. 29A includes a single frame arm 320a. FIG. 29B illustrates positioning assembly 300c attached along a side 2908 of building component 2904. Frame arm 320a of positioning assembly 300c abuts against side 2908. Frame arm 320a can enable an assembly robot to apply forces to control a bow or bend associated with side 2908. For example, frame arm 320a can enable application of a force to correct an initial bow of side 2908 illustrated by broken reference lines 2912a and 2912b.

[0222] In the illustrated embodiments, assembly frame 306 includes either one or two frame arms. In other embodiments, assembly frame 306 may include greater than two arms. For example, assembly frame 306 may include a greater number of arms to enable application of forces to a building structure with greater complexity compared with the illustrated examples.

[0223] In the illustrated embodiments, the first frame arm and the second frame arm are substantially perpendicular. In other embodiments, the first frame arm and the second frame arm may not be substantially perpendicular. For example, assembly frame 306 may include a first frame arm and a second frame arm that are not substantially perpendicular to match a non-right-angled corner of a building structure.

[0224] Assembly frame 306 may include any suitable attachment means 312 for attachment of positioning assembly 300 to the building component. In the illustrated embodiments, attachment means 312 includes multiple openings for fasteners to rigidly attach positioning assembly 300 to the building component. The number and type of fasteners may be selected based on the specific application. For example, the fasteners may be selected based on properties (e.g., size, material) of the building component and / or the amount of force to be applied to the building component via the positioning assembly. Any suitable fasteners may be used. For example, wood screws may be used to attach positioning assembly 300 to wooden building components. In some embodiments, attachment means 312 may include a different coupling mechanism. Forexample, attachment means 312 may include clamps for clamping positioning assembly 300 to the building component. As another example, an adhesive may be used to attach position assembly 300 to the building component.

[0225] In some embodiments, positioning assembly 300 further includes a position indicator 324 that indicates a position of the positioning assembly to an assembly robot. Any suitable technique may be utilized to implement position indicator 324.

[0226] In the illustrated embodiments, position indicator 324 includes multiple vision targets 324a-324c. Each vision target 324 may include a target mounted in a pocket formed in an upper surface of positioning assembly 300. Any suitable target may be used. In some embodiments, the target may be made of black Delrin plastic with a laser-etched marking on an upper side of the target. In other embodiments, a different type of vision target may be used.

[0227] The marking on the vision target may include a code, for example, a QR code or an AprilTag. In some embodiments, the code may be usable to uniquely identify the positioning assembly. In other embodiments, the code may not include any unique identification information for the positioning assembly. A position information detected using the vision target may be sufficient for automated assembly to be performed without requiring each positioning assembly to be uniquely identified.

[0228] Positioning assembly 300 may include any suitable number of vision targets 324. For example, a single vision target may be sufficient for position detection. A larger number of vision targets may provide redundancy and enable outlier identification and / or error correction during position detection. For example, a larger number of vision targets may mitigate position detection issues related to fluctuating lighting conditions and / or sawdust accumulation on the vision targets. A smaller number of vision targets may reduce the cost and / or complexity associated with the automated assembly.

[0229] In some embodiments, positioning assembly 300 may not include a position indicator. For example, the assembly robot may include an imaging device configured to capture images of positioning assembly 300. A processor may be configured to executea pose estimation algorithm to detect a position of positioning assembly 300 based on the captured images.

[0230] Reference is now made to FIGS. 30A-30C. FIG. 30A shows a perspective schematic diagram of an apparatus 400 for positioning a building component on an assembly surface during automated assembly by an assembly robot. FIG. 30B shows a top view schematic diagram of apparatus 400 and FIG. 30C shows a side view schematic diagram of apparatus 400.

[0231] Apparatus 400 includes a magnetic fixture and a positioning assembly. In the illustrated embodiment, apparatus 400 includes magnetic fixture 100u and positioning assembly 300a. In other embodiments, apparatus 400 may include other combinations of the magnetic fixture and the positioning assembly. For example, apparatus 400 may include magnetic fixture 100u and positioning assembly 300b. As another example, apparatus 400 may include magnetic fixture 100u and positioning assembly 300c.

[0232] As shown in FIGS. 30A-30C, magnetic fixture 100u may be connected to positioning assembly 300a by inserting coupling member 118 into opening 316. Positioning assembly 300a may be attached to a building component (e.g., building component 2704 shown in FIG. 27B). An assembly robot can grip apparatus 400 using gripping member 120 of magnetic fixture 100u. The assembly robot can further apply a force in an x-direction 3004 (shown in FIG. 30B) and / or y-direction 3008 (shown in FIG. 30B). The applied force can be transmitted through magnetic fixture 100u, through positioning assembly 300a (via the connection provided by coupling member 118) and to the building component. The assembly robot can use the applied force to control the x-y position of the building component on the assembly surface (e.g., assembly surface 2716 shown in FIG. 27B). For example, the assembly robot can use the applied force to change the position of corner 2712 (shown in FIG. 27B).

[0233] In some embodiments, the apparatus may include a gripper assembly that is mountable on an assembly robot. Reference is now made to FIG. 31 showing a perspective view of a robotic manipulator tool 3104, in accordance with an embodiment. The robotic manipulator tool can be mounted to the distal end of an assembly robot. Inthe illustrated embodiment, robotic manipulator tool 3104 includes a tool frame 3116, a robot interface 3112, and a gripper assembly 3108.

[0234] Tool frame 3116 can have any suitable design that provides sufficient rigidity and mechanical strength for mounting other components of robotic manipulator tool 3104. For example, tool frame 3116 may include a rigid aluminum frame that other components of robotic manipulator tool 3104 can be mounted to.

[0235] Robot interface 3112 can have any suitable design for automated connection of robotic manipulator tool 3104 with an assembly robot. Robot interface 3112 can enable automatic changing of the manipulator tool connected to the assembly robot based on the task to be performed by the assembly robot.

[0236] Gripper assembly 3108 may include any suitable gripper having one or more actuators to generate gripping force for gripping jaws connected to the gripper. The actuators may include, for example, a pneumatic actuator and / or an electric actuator. The gripper may be, for example, a Schunk® JGP-P 200-1 gripper or a Hitop® MHS63 gripper. In some embodiments, a different gripper may be used. The gripper jaws may have a complementary design to the gripping member of the magnetic fixture to enable the assembly robot to grip and move the magnetic fixture.

[0237] Reference is now made to FIG. 32, which shows a process flow for a method 3200 of use of magnetic fixtures for positioning a building component on an assembly surface during automated assembly by an assembly robot. While many of the examples included herein describe the automated assembly with reference to a floor cassette, method 3200 may be performed for automated assembly of any suitable building structure (for example, wall panels, roof trusses etc.).

[0238] Method 3200 may at least partially be performed by a system configured for automated assembly of building structures. For example, method 3200 may at least bepartially performed by system 1704 shown in FIG. 17 and concurrent reference is made herein below to system components illustrated in FIG. 17.

[0239] The automated assembly may be performed using a robotic assembly cell, for example, robotic assembly cell 1712 shown in FIG. 18. Concurrent reference is made herein below to robotic assembly cell components illustrated in FIG. 18.

[0240] The magnetic fixture used for positioning the building component can be, for example, magnetic fixture 100u shown in FIG. 26. Concurrent reference is made herein below to magnetic fixture components illustrated in FIG. 26.

[0241] At act 3204, method 3200 may include determining a current position of a building component on an assembly surface in relation to a target position. The building component may be, for example, a partially assembled building component that is transferred to robotic assembly cell 1712. The building component may be partially assembled in a different assembly cell using robotic and / or manual assembly.

[0242] For example, the building component may be a partially assembled floor cassette. The partially assembled floor cassette may have an initial frame assembled including joists, rim boards and beams. The partially assembled floor cassette may be transferred to robotic assembly cell 1712 for further assembly. The further assembly may include robotic assembly operations including, for example, gluing, sheathing application, joist alignment, nailing, and / or cutting.

[0243] Robots 1804 of assembly cell 1712 can perform one or more automated assembly operations on the building component. System 1704 may provide the control instructions for robots 1804 to perform the automated assembly operations. The control instructions may include robotic motion control commands that include position coordinates defined with reference to the assembly surface (e.g., assembly table 1812). The motion control commands may be based on the building component being in a target position on the assembly surface.

[0244] Reference is now made to FIG. 33, which shows a schematic diagram of a partially assembled floor cassette 3304 on an assembly table 1812. The target position of floor cassette 3304 on assembly table 1812 may be specified using coordinates 3308a-3308d that define a rectangle. The actual position of floor cassette 3304 on assembly table 1812 may be offset from the target position in x and / or y directions. For example, the entire floor cassette 3304 may be offset in an x-direction from the target position defined by coordinates 3308a-3308d. In such instances, the robotic motion control commands may need to be updated based on the offset between the current position and the target position of floor cassette 3304. This can increase complexity and / or cause errors during the automated assembly.

[0245] In some instances, some actual position coordinates of floor cassette 3304 may match the corresponding target position coordinates while other actual position coordinates of floor cassette 3304 may not match the corresponding target position coordinates. For the example illustrated in FIG. 33, the actual position coordinates of floor cassette 3304 match target position coordinates 3308a and 3308b. But the actual position coordinates 3312 and 3316 do not match target position coordinates 3308c and 3308d. This may be caused due to a skew / deformation of partially assembled floor cassette 3304. For example, the partially assembled floor cassette 3304 may not have sufficient rigidity and may be skewed / deformed during transfer to assembly table 1812. This skew / deformation may require to be corrected before further assembly operations can be performed.

[0246] Method 3200 can address the above-noted technical problems by enabling position control of the building component. One or more positioning assemblies may be attached to the building component. The positioning assemblies may be, for example, positioning assembly 300 shown in FIGS. 27A-29B. Concurrent reference is made herein below to positioning assembly components illustrated in FIGS. 27A-29B.

[0247] The positioning assemblies may be attached to the building component using any suitable method. Reference is now made to FIG. 34, which shows a process flow for a method 3400 of attachment of positioning assemblies to a building component. Method 3400 may at least partially be performed by a system configured for automated assembly of building structures, for example, system 1704.

[0248] At act 3404, method 3400 may include analyzing the assembly data associated with the building structure to determine an attachment location for each of the one or more positioning assemblies. For example, server 1716 may analyze the assembly data to determine an attachment location for each positioning assembly 300. The assembly data may be included, for example, in one or more design files 1724 received from user computer terminal 1708. Determining the attachment location can include determining a type of the positioning assembly and / or an attachment position of the positioning assembly on the building component.

[0249] Server 1716 may apply any suitable logic system and / or Al model to analyze the assembly data and determine the attachment location for each positioning assembly. In some embodiments, server 1716 may analyze all the sub-components of the building component to determine a topology of the building component. Further, server 1716 may select a datum point on the building component that serves as a reference position during the assembly process. Server 1716 may determine attachment locations for positioning assemblies by at least assigning a positioning assembly for attachment at the datum point. Server 1716 may further assign one or more additional positioning assemblies for attachment at other locations on the building component. In other embodiments, server 1716 may not attach a positioning assembly at the datum point.

[0250] Reference is now made to FIG. 35A showing a schematic diagram of a floor cassette 3504 and the determined attachment locations for multiple positioning assemblies 300. Based on the determined topology of floor cassette 3504, server 1716 may determine a corner location 3508 as the datum point and assign a positioning assembly of type 300a (shown in FIGS. 27A and 27B) for attachment at datum point 3508. Further, server 1716 may utilize a comprehensive corner support method and assign a positioning assembly for attachment at each of the other comers of floor cassette 3504.

[0251] The comprehensive corner support method can improve stability / rigidity of floor cassette 3504 during subsequent assembly. But this method can increase the number of positioning assemblies that must be attached, thereby increasing cost, complexity, and / or assembly time. Server 1716 may determine a type of positioningassembly (e.g., 300a / 300b) based on the determined topology. In the illustrated example, server 1716 may assign positioning assemblies 300ai-300as for attachment at outer comers of floor cassette 3504 and assign positioning assembly 300bi for attachment at an inner corner of floor cassette 3504. In some embodiments, server 1716 may assign a positioning assembly 300ci for attachment along a short edge 3512 connected to datum point 3508 of floor cassette 3504 to mitigate any potential deformation or bending in the framing elements.

[0252] Server 1716 may utilize the comprehensive corner support method for complex building components. For example, reference is now made to FIG. 35B showing a schematic diagram of a floor cassette 3516. Floor cassette 3516 may have a complex structural configuration where some framing components are not entirely covered by subfloors. Server 1716 may assign a positioning assembly 300 for attachment at each corner of floor cassette 3516. In the illustrated example, server 1716 may assign positioning assemblies 300ai-300ae for attachment at outer corners of floor cassette 3516 and positioning assemblies 300bi-300b4 for attachment at inner corners of floor cassette 3516.

[0253] Reference is now made to FIG. 35C showing a schematic diagram of floor cassette 3504 and the determined attachment locations by server 1716 utilizing an alternating corner support method. Server 1716 may determine a corner location 3508 as the datum point and assign positioning assembly 300ai for attachment at datum point 3508. Server 1716 may further assign a positioning assembly for attachment at alternating comers starting from datum point 3508 and proceeding in a clockwise direction. In the illustrated example, server 1716 may assign positioning assemblies 300ai-300a3 for attachment at outer corner of floor cassette 3504. In some embodiments, server 1716 may further assign a positioning assembly 300ci for attachment along short edge 3512 connected to datum point 3508.

[0254] The alternating corner support method can reduce the number of positioning assemblies compared with the comprehensive corner support method. The alternating corner support method can thereby reduce cost, complexity, and / or assembly time compared with the comprehensive corner support method.

[0255] Reference is now made to FIG. 35D showing a schematic diagram of floor cassette 3504 and the determined attachment locations by server 1716 utilizing a datumside corner support method. Server 1716 may determine a corner location 3508 as the datum point and assign positioning assembly 300ai for attachment at datum point 3508. Server 1716 may assign further positioning assemblies only along shorter edge 3512 connected to datum point 3508. In the illustrated example, server 1716 may assign positioning assembly 300a2 and 300ci for attachment along short edge 3512.

[0256] The datum-side corner support method can reduce the number of positioning assemblies compared with the comprehensive corner support method and the alternating corner support method. The datum-side corner support method can thereby reduce cost, complexity, and / or assembly time compared with the comprehensive corner support method and the alternating corner support method. The datum-side corner support method may provide sufficient stability / rigidity for some building components. For example, the datum-side corner support method may be sufficient for simple, semi- rectangular floor cassettes that do not have any complex structural features (e.g., stairway openings).

[0257] Referring back now to FIG. 34, at act 3408, method 3400 may include attaching the one or more positioning assemblies to the building component at the attachment location determined at act 3404. Any suitable technique may be used for attachment of the positioning assemblies to the building component. In some embodiments, the positioning assemblies may be manually attached (e.g., using wood screws) to the building component. The building component with the attached positioning assemblies may then be transferred to robotic assembly cell 1712 for further assembly.

[0258] Referring back now to FIG. 32 and method 3200, at act 3204, a processor can determine a current position of the building component having one or more attached positioning assemblies. The processor may include for example, server 1716 and / or a local computing system of the robotic assembly cell.

[0259] In some embodiments, the processor may determine the current position of the building component in relation to a target position by detecting the position of thepositioning assemblies attached to the building component. Further, the processor can utilize the detected position of the positioning assemblies and the known geometry of attachment of the positioning assemblies to determine the current position of the building component. Reference is now additionally made to FIG. 36A, which shows a schematic diagram of a floor cassette 3604 on an assembly table 1812. In the illustrated example, a positioning assembly 300 is attached to each corner of floor cassette 3604. The processor can determine the current location and orientation of floor cassette 3604 by detecting the position of each positioning assembly 300. In other embodiments, the processor may directly determine the current position of the building component in relation to the target position without detecting the positioning assemblies.

[0260] In some embodiments, an imaging device may be mounted on assembly robot 1804. Assembly robot 1804 may detect the position of a positioning assembly 300 by capturing one or more images of that positioning assembly 300. In some embodiments, vision targets 324 (e.g., shown in FIGS. 27A, 28A and 29A) may be located on positioning assembly 300. The processor may apply any suitable computer vision algorithm to detect vision target 324 in the captured images.

[0261] Assembly robot 1804 may execute control instructions to move to an image capture position corresponding to an expected position of the positioning assembly and at a predetermined height above assembly table 1812. The expected position of the positioning assembly can be determined based on the target location for the building component and the attachment position of the positioning assembly on the building component. Any suitable height above assembly table 1812 may be used. For example, the imaging device may have a field-of-view (FOV) of 600x400mm at an image capture height of 600mm above assembly table 1812. However, the imaging device may have a smaller effective FOV (e.g., 500x300mm) for enabling accurate position measurements using captured images. Assembly robot 1804 may move to different positions until positioning assembly 300 is located within the effective FOV. In some embodiments, assembly robot 1804 may initially use a larger height above assembly table 1812 to have a larger initial FOV for locating positioning assembly 300 on assembly table 1812.Assembly robot 1804 may then move to a lower height to capture images with positioning assembly 300 located within the effective FOV.

[0262] Reference is now made to FIGS. 37A, 37B, and 37C, which show example captured images 3704, 3708, and 3712 respectively of a positioning assembly 300 having vision targets 324a-324c. Images 3704, 3708, and 3712 are captured under varying lighting conditions and levels of sawdust accumulation. In each example, the assembly robot can successfully locate positioning assembly 300 approximately centrally within the capture image so that vision targets 324 are within the effective FOV of the imaging device.

[0263] Referring back now to FIG. 32, at act 3208, method 3200 may include determining if a repositioning is needed so that the building component is in the target position. For example, the processor can determine if any of the positioning assemblies attached to the building component need to be repositioned so that the building component is in the target position. The processor can apply any suitable logic system and / or Al model to determine if a repositioning is needed based on the current position of the building component in relation to the target position. In some instances, a repositioning may be needed to change an orientation and / or a location of the building component on the assembly surface. For the example illustrated in FIG. 36A, the processor may determine that each corner of floor cassette 3604 needs an x-direction shift so that the building component reaches the target position. In some instances, the repositioning may be for changing a position of a portion of the building component. For example, the processor may determine that a corner 3608 needs to be shifted to correct a skewness / misalignment of floor cassette 3604.

[0264] In response to determining that a repositioning is needed, method 3200 may proceed to act 3212. If no repositioning is needed, method 3200 may directly proceed to act 3224.

[0265] At act 3212, method 3200 may include moving a magnetic fixture connected to a positioning assembly (that needs repositioning) to a predetermined position. The processor may provide the predetermined position to an assembly robot. The assemblyrobot may execute received robotic control instructions to move the magnetic fixture, thereby changing the position of the building component via the connection through the positioning assembly.

[0266] Reference is now additionally made to FIG. 36B, which shows a schematic diagram of floor cassette 3604 having a positioning assembly 300 attached to each corner. Magnetic fixtures may be connected to the positioning assemblies at any suitable stage of method 3200. In some embodiments, the magnetic fixtures may be connected to the positioning assemblies before determining (at act 3204) the current position of the building component in relation to a target position. In the illustrated example, a magnetic fixture 100u is connected to each positioning assembly 300, regardless of whether that positioning assembly needs any repositioning. This may increase the number of magnetic fixtures utilized and increase the assembly time. However, this may provide improved stability / rigidity when the magnets are toggled ON (at act 3216) to secure the building component in the target position for further assembly.

[0267] In some embodiments, a magnetic fixture may be connected to only the positioning assemblies that need to be repositioned. This may reduce the number of magnetic fixtures utilized and reduce the assembly time. However, this may provide reduced stability / rigidity when the magnets are toggled ON (at act 3216) to secure the building component (compared with connecting magnetic fixtures at each positioning assembly).

[0268] At act 3216, method 3200 may include toggling a magnet of the magnetic fixture from an OFF state to an ON state. This can fix the position of the magnetic fixture, the connected positioning assembly and the corresponding portion (e.g., corner 3608) of the building component. In some embodiments, assembly robot 1804 may use a magnet actuator (e.g., magnet actuator 1008 shown in FIGS. 10 and 11 ) to toggle the magnetic fixtures to the ON state.

[0269] Method 3200 may further proceed to act 3220 to determine if additional magnetic fixtures (and the corresponding positioning assemblies) need to be moved so that the building component is in the target position. If any additional magnetic fixtureneeds to be moved, method 3200 may proceed to act 3212 to move another magnetic fixture. If no additional magnetic fixtures need to be moved, method 3200 may proceed to act 3224.

[0270] At act 3224, method 3200 may include toggling the magnets (of any magnetic fixtures) that are in an OFF state to an ON state. This can fix the position of all magnetic fixtures (and the corresponding positioning assemblies) including the magnetic fixtures that were not moved during the repositioning. This can enable the magnetic fixtures to support the building component (via the connected positioning assembly) and prevent movement of the building component during further assembly operations (e.g., cutting, joist alignment, etc.).

[0271] At act 3228, the assembly robot may perform further assembly operations with the building component secured in the target position. For example, the further assembly operations may include gluing, sheathing application, joist alignment, nailing, and / or cutting operations. After the further assembly operations are complete, the building component may be removed from the robotic assembly cell.

[0272] In some embodiments, after assembly operations are complete, the magnets may be toggled from an ON state to an OFF state. The magnetic fixtures may then be disconnected from the positioning assemblies and removed from the assembly surface. Further, the assembled building component may be removed from the robotic assembly cell. The positioning assemblies may be detached from the assembled building component before or after the building component is removed from the robotic assembly cell.

[0273] In some instances, the further assembly operation for the building component may result in the magnetic fixtures being blocked from removal. For example, one or more of the magnetic fixtures may be covered by overhung subfloor sheets that makes it difficult for the assembly robots to access the magnetic fixtures. The disclosed systems, methods and devices can address this challenge by enabling the assembled building component to be lifted using pop-up rollers in the assembly table. A coupling pinbased connection between the magnetic fixture and the positioning assembly can enablethe assembled building component, including the positioning assemblies, to be lifted off while the magnetic fixtures remain attached (with magnets staying in ON state) to the assembly table. The assembled building component can then be rolled over, above the magnetic fixtures, and out of the robotic assembly cell. Subsequently, the magnets may be toggled from an ON state to an OFF state and the magnetic fixtures can be removed from the assembly surface.

[0274] While the above description describes features of example embodiments, it will be appreciated that some features and / or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. For example, the various characteristics which are described by means of the represented embodiments or examples may be selectively combined with each other. Accordingly, what has been described above is intended to be illustrative of the claimed concept and non-limiting. It will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto. The scope of the claims should not be limited by the preferred embodiments and examples, but should be given the broadest interpretation consistent with the description as a whole.CLAUSES:Clause 1 : A magnetic fixture to position a building component on an assembly surface during automated assembly by an assembly robot, the magnetic fixture comprising: a magnet toggleable between an ON state and an OFF state; and a fixture frame coupled to the magnet, the fixture frame comprising: a coupling member to form a detachable connection with a positioning assembly attached to the building component; and a gripping member having one or more gripping surfaces for gripping by the assembly robot, the assembly robot being configured to move the magnetic fixture to control the position of the building component on the building surface.Clause 2: The magnetic fixture according to any of the preceding clauses, wherein the coupling member comprises a coupling pin that mates with an opening in the positioning assembly to form the detachable connection.Clause 3: The magnetic fixture according to any of the preceding clauses, wherein the one or more gripping surfaces include a set of four angled surfaces, which when contacted by one or more gripper jaws of the assembly robot, pull the gripping member towards the assembly robot for secure gripping.Clause 4: The magnetic fixture according to any of the preceding clauses, wherein the gripping member further comprises one or more alignment surfaces for alignment during gripping by the assembly robot.Clause 5: The magnetic fixture according to any of the preceding clauses, wherein the one or more alignment surfaces include a pair of angled lateral centering surfaces.Clause 6: The magnetic fixture according to any of the preceding clauses, wherein the fixture frame is removably coupled to the magnet.Clause 7: The magnetic fixture according to any of the preceding clauses, wherein the magnet is mechanically toggleable.Clause 8: The magnetic fixture according to any of the preceding clauses, wherein the magnet is electronically toggleable.Clause 9: The magnetic fixture according to any of the preceding clauses, wherein the magnet is electronically toggleable using a wireless control signal.Clause 10: The magnetic fixture according to any of the preceding clauses, further comprising a presence fixture or a presence sensor that is usable by the assembly robot to detect a presence and / or a position of the magnetic fixture.Clause 11 : The magnetic fixture according to any of the preceding clauses, wherein the presence sensor comprises a retroreflector, and the assembly robot includes a corresponding retroreflective optical sensor to detect the presence and / or the position of the magnetic fixture.Clause 12: A positioning assembly to position a building component on an assembly surface during automated assembly by an assembly robot, the positioning assembly comprising: an assembly frame including an attachment means for attachment of the positioning assembly to the building component; and a fixture coupler to form a detachable connection with a magnetic fixture, the assembly robot being configured to move the magnetic fixture to control the position of the building component on the building surface.Clause 13: The positioning assembly according to any of the preceding clauses, wherein the fixture coupler comprises an opening that can receive a coupling pin of the magnetic fixture to form the detachable connection.Clause 14: The positioning assembly according to any of the preceding clauses, wherein the assembly frame further includes a first frame arm that abuts against the building component when the positioning assembly is attached to the building component.Clause 15: The positioning assembly according to any of the preceding clauses, wherein the assembly frame further includes a second frame arm that is substantially perpendicular to the first frame arm, each of the first frame arm and the second frame arm abutting against the building component when the positioning assembly is attached to the building component.Clause 16: The positioning assembly according to any of the preceding clauses, wherein the positioning assembly further comprises a position indicator that indicates a position of the positioning assembly to the assembly robot.Clause 17: The positioning assembly according to any of the preceding clauses, wherein the position indicator includes one or more vision targets, and the assembly robot is configured to determine the position by detecting at least one of the one or more vision targets.Clause 18: An apparatus for positioning a building component on an assembly surface during automated assembly by an assembly robot, the apparatus comprising: a magnetic fixture according to any of the preceding clauses; and a positioning assembly according to any of the preceding clauses.Clause 19: The apparatus according to any of the preceding clauses, further comprising a gripper assembly to grip and move the magnetic fixture to control the position of the building component, the gripper assembly being mountable on the assembly robot.Clause 20: A method of use of magnetic fixtures for positioning a building component on an assembly surface during automated assembly by an assembly robot, the method comprising: determining a current position of the building component on the assembly surface in relation to a target position, one or more positioning assemblies being attached to the building component; determining if a repositioning is needed so that the building component is in the target position; in response to determining that a repositioning is needed, moving a magnetic fixture to a predetermined position, wherein the magnetic fixture is connected to at least one of the one or more positioning assemblies; and toggling a magnet of the magnetic fixture from an OFF state to an ON state to secure the building component in the target position.Clause 21 : The method according to any of the preceding clauses, further comprising: analyzing assembly data associated with the building component to determine an attachment location for each of the one or more positioning assemblies; and attaching the one or more positioning assemblies to the building component at the determined attachment location.Clause 22: The method according to any of the preceding clauses, wherein determining the attachment location comprises determining a type of the positioning assembly to be attached at that attachment location.Clause 23: The method according to any of the preceding clauses, wherein determining the current position of the building component comprises determining position of each of the one or more positioning assemblies.Clause 24: The method according to any of the preceding clauses, wherein repositioning the building component to the target position comprises moving the entire building component from the current position to the target position to control at least one of a location and an orientation of the building component.Clause 25: The method according to any of the preceding clauses, wherein repositioning the building component to the target position comprises moving a first portion of the building component in relation to a second portion of the building component to control at least one of a skewness and a misalignment of the building component.Clause 26: The method according to any of the preceding clauses, wherein the building component comprises a floor cassette.Clause 27: A magnetic fixture to support building components during automated assembly, the magnetic fixture comprising: a magnet toggleable between an ON state and an OFF state; and a fixture frame attached to the magnet, the fixture framecomprising one or more frame surfaces to support the building components during the automated assembly.Clause 28: The magnetic fixture according to any of the preceding clauses, wherein the magnetic fixture further comprises a gripping member including: one or more gripping surfaces for gripping by one or more gripper jaws of an assembly robot; and one or more alignment surfaces for alignment during the gripping by the assembly robot.Clause 29: The magnetic fixture according to any of the preceding clauses, wherein the one or more gripping surfaces include a set of four angled surfaces, which when contacted by the one or more gripper jaws, pull the gripping member towards the assembly robot for secure gripping.Clause 30: The magnetic fixture according to any of the preceding clauses, wherein the one or more alignment surfaces include a pair of angled lateral centering surfaces.Clause 31 : The magnetic fixture according to any of the preceding clauses, wherein the building components are supported on an assembly table during the automated assembly. The assembly table can have a horizontal orientation, a vertical orientation or a different orientation.Clause 32: The magnetic fixture according to any of the preceding clauses, wherein the frame is removably attached to the magnet.Clause 33: The magnetic fixture according to any of the preceding clauses, wherein the magnet is mechanically toggleable.Clause 34: The magnetic fixture according to any of the preceding clauses, wherein the magnet is electronically toggleable.Clause 35: The magnetic fixture according to any of the preceding clauses, wherein the magnet is electronically toggleable using a wireless control signal.Clause 36: The magnetic fixture according to any of the preceding clauses, wherein the magnetic fixture comprises multiple toggleable magnets.Clause 37: The magnetic fixture according to any of the preceding clauses, further comprising a presence fixture or a presence sensor usable by an assembly robot to detect a presence and / or a position of the magnetic fixture.Clause 38: The magnetic fixture according to any of the preceding clauses, wherein the presence sensor comprises a retroreflector, and the assembly robot includes a corresponding retroreflective optical sensor to detect the presence and / or the position of the magnetic fixture.Clause 39: A system for automated assembly of a building structure, the system comprising: one or more magnetic fixtures, each magnetic fixture according to any one of the preceding clauses; and a gripper assembly mountable to an assembly robot configured for the automated assembly of the building structure, the gripper assembly comprising one or more gripper jaws to grip the one or more magnetic fixtures.Clause 40: The system according to any of the preceding clauses, wherein the gripper assembly further comprises an imaging device configured to capture images of the one or more magnetic fixtures, and the system further comprises a processor executing a pose detection algorithm to detect a position of the one or more magnetic fixtures based on the captured images.Clause 41 : The system according to any of the preceding clauses, further comprising a storage unit to store the one or more magnetic fixtures.Clause 42: A method of use of magnetic fixtures to support building components on an assembly table during automated assembly of a building structure, the method comprising: analyzing assembly data associated with the building structure to determine a magnetic fixture arrangement to support the building components during automated assembly of the building structure, the determined magnetic fixture arrangement including at least one of a number, a type, an assembly table position, an assembly tableorientation, and a sequence of positioning and removal of the magnetic fixtures; positioning the magnetic fixtures on the assembly table based on the determined magnetic fixture arrangement; positioning the building components on the assembly table using the magnetic fixtures to support the building components; assembling the building components to form the building structure; and removing the magnetic fixtures from the assembly table.

Claims

CLAIMS:1 . A magnetic fixture to position a building component on an assembly surface during automated assembly by an assembly robot, the magnetic fixture comprising: a magnet toggleable between an ON state and an OFF state; and a fixture frame coupled to the magnet, the fixture frame comprising: a coupling member to form a detachable connection with a positioning assembly attached to the building component; and a gripping member having one or more gripping surfaces for gripping by the assembly robot, the assembly robot being configured to move the magnetic fixture to control the position of the building component on the building surface.

2. The magnetic fixture of claim 1 , wherein the coupling member comprises a coupling pin that mates with an opening in the positioning assembly to form the detachable connection.

3. The magnetic fixture of claim 1 or claim 2, wherein the one or more gripping surfaces include a set of four angled surfaces, which when contacted by one or more gripper jaws of the assembly robot, pull the gripping member towards the assembly robot for secure gripping.

4. The magnetic fixture of any one of claims 1 to 3, wherein the gripping member further comprises one or more alignment surfaces for alignment during gripping by the assembly robot.

5. The magnetic fixture of claim 4, wherein the one or more alignment surfaces include a pair of angled lateral centering surfaces.

6. The magnetic fixture of any one of claims 1 to 5, wherein the fixture frame is removably coupled to the magnet.

7. The magnetic fixture of any one of claims 1 to 6, wherein the magnet is mechanically toggleable.

8. The magnetic fixture of any one of claims 1 to 6, wherein the magnet is electronically toggleable.

9. The magnetic fixture of claim 8, wherein the magnet is electronically toggleable using a wireless control signal.

10. The magnetic fixture of any one of claims 1 to 9, further comprising a presence fixture or a presence sensor that is usable by the assembly robot to detect a presence and / or a position of the magnetic fixture.

11. The magnetic fixture of claim 10, wherein the presence sensor comprises a retroreflector, and the assembly robot includes a corresponding retroreflective optical sensor to detect the presence and / or the position of the magnetic fixture.

12. A positioning assembly to position a building component on an assembly surface during automated assembly by an assembly robot, the positioning assembly comprising: an assembly frame including an attachment means for attachment of the positioning assembly to the building component; and a fixture coupler to form a detachable connection with a magnetic fixture, the assembly robot being configured to move the magnetic fixture to control the position of the building component on the building surface.

13. The positioning assembly of claim 12, wherein the fixture coupler comprises an opening that can receive a coupling pin of the magnetic fixture to form the detachable connection.

14. The positioning assembly of claim 12 or claim 13, wherein the assembly frame further includes a first frame arm that abuts against the building component when the positioning assembly is attached to the building component.

15. The positioning assembly of claim 14, wherein the assembly frame further includes a second frame arm that is substantially perpendicular to the first frame arm, each of the first frame arm and the second frame arm abutting against the building component when the positioning assembly is attached to the building component.

16. The positioning assembly of any one of claims 12 to 15, wherein the positioning assembly further comprises a position indicator that indicates a position of the positioning assembly to the assembly robot.

17. The positioning assembly of claim 16, wherein the position indicator includes one or more vision targets, and the assembly robot is configured to determine the position by detecting at least one of the one or more vision targets.

18. An apparatus for positioning a building component on an assembly surface during automated assembly by an assembly robot, the apparatus comprising: a magnetic fixture according to any one of claims 1 to 1 1 ; and a positioning assembly according to any one of claims 12 to 17.

19. The apparatus of claim 18, further comprising a gripper assembly to grip and move the magnetic fixture to control the position of the building component, the gripper assembly being mountable on the assembly robot.

20. A method of use of magnetic fixtures for positioning a building component on an assembly surface during automated assembly by an assembly robot, the method comprising: determining a current position of the building component on the assembly surface in relation to a target position, one or more positioning assemblies being attached to the building component; determining if a repositioning is needed so that the building component is in the target position;in response to determining that a repositioning is needed, moving a magnetic fixture to a predetermined position, wherein the magnetic fixture is connected to at least one of the one or more positioning assemblies; and toggling a magnet of the magnetic fixture from an OFF state to an ON state to secure the building component in the target position.21 . The method of claim 20, further comprising: analyzing assembly data associated with the building component to determine an attachment location for each of the one or more positioning assemblies; and attaching the one or more positioning assemblies to the building component at the determined attachment location.

22. The method of claim 21 , wherein determining the attachment location comprises determining a type of the positioning assembly to be attached at that attachment location.

23. The method of any one of claims 20 to 22, wherein determining the current position of the building component comprises determining position of each of the one or more positioning assemblies.

24. The method of any one of claims 20 to 23, wherein repositioning the building component to the target position comprises moving the entire building component from the current position to the target position to control at least one of a location and an orientation of the building component.

25. The method of any one of claims 20 to 23, wherein repositioning the building component to the target position comprises moving a first portion of the building component in relation to a second portion of the building component to control at least one of a skewness and a misalignment of the building component.

26. The method of any one of claims 20 to 25, wherein the building component comprises a floor cassette.

27. A magnetic fixture to support building components during automated assembly, the magnetic fixture comprising: a magnet toggleable between an ON state and an OFF state; and a fixture frame attached to the magnet, the fixture frame comprising one or more frame surfaces to support the building components during the automated assembly.

28. The magnetic fixture of claim 27, wherein the magnetic fixture further comprises a gripping member including: one or more gripping surfaces for gripping by one or more gripper jaws of an assembly robot; and one or more alignment surfaces for alignment during the gripping by the assembly robot.

29. The magnetic fixture of claim 28, wherein the one or more gripping surfaces include a set of four angled surfaces, which when contacted by the one or more gripper jaws, pull the gripping member towards the assembly robot for secure gripping.

30. The magnetic fixture of claim 28, wherein the one or more alignment surfaces include a pair of angled lateral centering surfaces.

31. The magnetic fixture of any one of claims 27 to 30, wherein the building components are supported on an assembly table during the automated assembly.

32. The magnetic fixture of any one of claims 27 to 31 , wherein the frame is removably attached to the magnet.

33. The magnetic fixture of any one of claims 27 to 32, wherein the magnet is mechanically toggleable.

34. The magnetic fixture of any one of claims 27 to 32, wherein the magnet is electronically toggleable.

35. The magnetic fixture of claim 34, wherein the magnet is electronically toggleable using a wireless control signal.

36. The magnetic fixture of any one of claims 27 to 35, wherein the magnetic fixture comprises multiple toggleable magnets.

37. The magnetic fixture of any one of claims 27 to 36, further comprising a presence fixture or a presence sensor usable by an assembly robot to detect a presence and / or a position of the magnetic fixture.

38. The magnetic fixture of claim 37, wherein the presence sensor comprises a retroreflector, and the assembly robot includes a corresponding retroreflective optical sensor to detect the presence and / or the position of the magnetic fixture.

39. A system for automated assembly of a building structure, the system comprising: one or more magnetic fixtures, each magnetic fixture according to any one of claims 27 to 38; and a gripper assembly mountable to an assembly robot configured for the automated assembly of the building structure, the gripper assembly comprising one or more gripper jaws to grip the one or more magnetic fixtures.

40. The system of claim 39, wherein the gripper assembly further comprises an imaging device configured to capture images of the one or more magnetic fixtures, and the system further comprises a processor executing a pose detection algorithm to detect a position of the one or more magnetic fixtures based on the captured images.41 . The system of claim 39 or claim 40, further comprising a storage unit to store the one or more magnetic fixtures.

42. A method of use of magnetic fixtures to support building components on an assembly table during automated assembly of a building structure, the method comprising: analyzing assembly data associated with the building structure to determine a magnetic fixture arrangement to support the building components during automated assembly of the building structure, the determined magnetic fixture arrangement including at least one of a number, a type, an assembly table position, an assembly table orientation, and a sequence of positioning and removal of the magnetic fixtures; positioning the magnetic fixtures on the assembly table based on the determined magnetic fixture arrangement; positioning the building components on the assembly table using the magnetic fixtures to support the building components; assembling the building components to form the building structure; and removing the magnetic fixtures from the assembly table.

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