Adaptive Building Component Manufacturing With Scan Feedback
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Solution Overview
Problem
Existing construction methods using pre-manufactured building components face significant manufacturing precision issues, leading to cumulative errors and inconsistencies due to deviations from design parameters, which hinder automation and increase costs through manual adjustments.
Innovation Solution
An adaptive manufacturing method utilizing digital information models, scanning technologies, and real-time recalculations to adjust manufacturing parameters based on actual component dimensions, ensuring precise assembly and enabling automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high manufacturing precision is required for building components, then assembly quality is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The system performs preliminary scanning and measurement of building components before assembly, creating a digital representation that captures actual dimensions. This preliminary action allows for pre-calculation of adjustments needed in subsequent components, preventing cumulative errors without requiring extreme manufacturing precision at each stage
Solution Approach 2:
The system implements a feedback loop where scanned data from manufactured components is fed back into the digital information model, which then recalculates and adjusts parameters for remaining components. This continuous feedback mechanism compensates for manufacturing variations dynamically, reducing the need for high initial manufacturing precision
2Manufacturing precision
If manual adjustments are made during assembly to eliminate parameter deviations, then assembly quality is improved, but assembly time and costs increase
Solution Approach 1:
The system automatically detects deviations through scanning and feeds this information back to recalculate parameters for remaining components, eliminating the need for manual measurement and adjustment during assembly
Solution Approach 2:
The system replaces manual mechanical adjustment processes with automated digital recalculation and robotic positioning. The digital information model automatically computes compensation parameters, and robotic systems execute the adjustments without human intervention, dramatically reducing assembly time
3Manufacturing precision
If manual fitting and grinding are performed to correct deviations, then assembly quality is improved, but automation capability is reduced
Solution Approach 1:
The system replaces manual fitting and grinding operations with automated robotic systems. Robotic manipulators equipped with scanning capabilities perform measurement, and other robots execute automated adjustment operations based on digital calculations, fully automating processes that were previously requiring skilled manual labor
Solution Approach 2:
The system enables self-service automation where robotic systems autonomously perform scanning, data processing, calculation of compensation parameters, and physical adjustment of components without human intervention, making the assembly process fully automated and adaptable to variations
4Measurement precision
If digital building modeling systems are used for design and assembly planning, then design accuracy is improved, but consistency with actual manufacturing is reduced
Solution Approach 1:
The system bridges the gap between design and manufacturing by implementing feedback from actual scanned components back to the digital information model. The model is dynamically updated with measured data and recalculates parameters for remaining components, ensuring consistency between design intent and actual manufactured parts
Solution Approach 2:
The digital information model transitions from a static design representation to a dynamic system that continuously updates based on actual manufacturing outcomes. Parameters are recalculated in real-time based on feedback from scanning, allowing the model to adapt to actual component variations while maintaining overall design consistency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Minimizes cumulative errors, reduces precision requirements, lowers costs, and facilitates automated assembly by compensating for deviations in real-time, enhancing the quality and efficiency of construction processes.
Implementation Method 1
scanning at least one manufactured building component using at least one of laser scanning, or structured light scanning, or ultrasound-based scanning
Implementation Method 2
scanning at least one manufactured building component using at least one of laser scanning, or structured light scanning, or ultrasound-based scanning
Implementation Method 3
scanning at least one manufactured building component using at least one of laser scanning, or structured light scanning, or ultrasound-based scanning
Data Source
AI summary
The present invention relates to an adaptive manufacturing method for building components, particularly in prefabrication, modular construction, and panelized construction. The invention minimizes cumulative errors in building component production, enhances precision, and facilitates automated assembly using real-time digital updates. The method includes creating a digital information model of a building, containing data on the dimensions and positions of building components; manufacturing at least one building component based on initial model parameters; scanning the manufactured component using laser scanning, structured light scanning, or ultrasound-based scanning, selected based on the material properties, to generate a digital representation of its actual dimensions and shape; updating the digital model with the scanned data to dynamically adjust parameters for subsequent components; recalculating and adjusting the parameters of unmanufactured components based on detected deviations; transmitting adjusted parameters to an automated manufacturing system for real-time modifications in production. The system comprises a processor executing adaptive manufacturing instructions, a scanning module, a processing unit, and a recalculation module that updates component dimensions based on deviations, ensuring seamless integration of prefabricated elements.