Angled-Surface Robotic Material Handling With Cable Anchors
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Solution Overview
Problem
The construction industry faces labor shortages and inefficiencies in tasks such as roof installation and maintenance, particularly for installing shingles and solar panels, due to repetitive, low-paying, and dangerous manual labor, which are exacerbated by the increasing demand for climate-related repairs and installations.
Innovation Solution
A system comprising an apparatus with a body assembly, arm assembly, and end effector assembly, utilizing anchor assemblies and cables to operate on angled surfaces, allowing for automated placement and removal of materials like shingles and solar panels, with a controller managing the system's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used for roof installation and maintenance, then flexibility and adaptability are maintained, but labor intensity and danger increase while productivity remains low
Solution Approach 1:
The automated roof installation system is divided into separate functional modules: a mobile platform for movement, an arm assembly with multiple degrees of freedom for positioning, an end effector for material handling, and a control system. This segmentation allows each component to be optimized independently while maintaining overall system functionality, resolving the contradiction between automation and complexity.
Solution Approach 2:
The system incorporates autonomous navigation capabilities where the mobile platform autonomously moves to required positions on the roof using sensors and control algorithms. The arm assembly automatically positions and installs materials without continuous human intervention, enabling the system to serve itself and significantly increasing productivity while reducing manual labor.
2Manufacturing precision
If automated systems are implemented for roof operations, then productivity and precision increase, but device complexity and initial costs increase
Solution Approach 1:
The system incorporates sensors and control systems that provide real-time feedback on the position and orientation of the arm assembly and end effector. This feedback loop enables precise control of material placement by continuously monitoring and adjusting the system's state, achieving high manufacturing precision while managing complexity through automated control rather than mechanical complexity.
Solution Approach 2:
The arm assembly is designed with multiple degrees of freedom allowing dynamic adjustment of position and orientation. This dynamic capability enables the system to adapt to different roof geometries and material types, achieving precise material placement across varied conditions without requiring multiple specialized systems, thus managing overall complexity.
3Productivity
If manual material handling is used, then equipment simplicity is maintained, but labor intensity and operational costs increase
Solution Approach 1:
The end effector is designed to autonomously grasp, lift, position, and install roofing materials without human intervention. The system self-manages the complete material handling process from pickup to installation, dramatically increasing installation rates while reducing the need for skilled manual labor and simplifying operational requirements.
Solution Approach 2:
Manual mechanical operations are replaced with an automated robotic system comprising an arm assembly and end effector controlled by a computer system. This substitution eliminates the need for workers to manually handle heavy materials at heights, increasing productivity while the control system manages operational complexity, making the overall process easier to operate consistently.
4Reliability
If workers perform roof installation manually, then equipment requirements are minimal, but safety risks and labor shortages worsen
Solution Approach 1:
The control system continuously monitors the installation process through sensors that detect material position, arm orientation, and placement accuracy. This real-time feedback ensures consistent installation quality by automatically adjusting parameters to maintain specifications, improving reliability while the automated control manages system complexity rather than requiring complex mechanical tolerances.
Solution Approach 2:
The system autonomously performs all installation operations without human workers on the roof, eliminating safety risks associated with manual work at heights. The robotic arm and end effector self-manage material handling and installation, ensuring consistent quality through programmed precision while reducing dependency on skilled labor availability.
Data Source
AI summary
Apparatuses configured to operate on an angled surface and associated systems and methods are disclosed herein. In some embodiments, an apparatus includes a body assembly, an arm assembly, and an end effector assembly. The body assembly can include a body portion, one or more wheels, one or more motors coupled to corresponding ones of the one or more wheels, and a plurality of cable connectors coupled to the rail. Individual ones of the cable connectors are configured to be coupled to corresponding cables. The arm assembly can be coupled to the body portion of the body assembly and can include a retriever. The end effector assembly can be releasably coupled to the retriever of the arm assembly and configured to carry a surface material.