Concrete Surface Mapping Robot Using Laser Height And Tilt Detection
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Solution Overview
Problem
Current concrete surface processing technologies lack efficient and cost-effective methods for autonomous or semi-autonomous mapping and processing of concrete surfaces, particularly in achieving uniform height and tilt detection, which is crucial for reliable and accurate surface preparation.
Innovation Solution
A concrete surface processing machine equipped with a control unit connected to linear photo sensors that detect the height of an incoming laser beam and adjust self-locomotion based on detected height differences, allowing for accurate topology mapping and selective processing, while also incorporating features for tool wear detection and dust collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mapping methods are used for concrete surface processing, then the mapping can be performed, but the cost is high and the efficiency is low
Solution Approach 1:
The processing machine is equipped with both processing tools (grinding discs, polishing pads) and mapping sensors (linear photo sensors, lasers) to perform multiple functions including surface processing and topology mapping. This multi-functionality eliminates the need for separate mapping equipment, reducing overall system complexity while improving productivity.
Solution Approach 2:
The patent replaces traditional mechanical/optical mapping systems with a laser-based optical system combined with linear photo sensors. The laser projects a plane onto the surface, and the linear photo sensors detect the reflected light patterns to determine surface topology, providing a more efficient and less complex mapping approach compared to traditional mechanical scanning systems.
2Extent of automation
If autonomous processing is implemented, then manual intervention is reduced, but the precision of height and tilt detection must be improved
Solution Approach 1:
The control unit continuously receives height and tilt data from the linear photo sensors during processing, compares the detected surface topology against the desired finish specifications, and automatically adjusts the processing machine's position, orientation, and tool engagement. This closed-loop feedback system enables autonomous operation while maintaining high measurement precision through real-time corrections.
Solution Approach 2:
The system uses a laser plane projected onto the surface combined with linear photo sensors arranged in multiple dimensions to detect both height variations and tilt angles. By analyzing the spatial distribution of reflected light across the linear sensor array, the system extracts three-dimensional surface information including vertical height and angular orientation, achieving comprehensive precision measurement for autonomous control.
3Ease of manufacture
If linear photo sensors are used for height detection, then the cost is reduced, but the precision of surface mapping must be maintained
Solution Approach 1:
The laser plane acts as an intermediary reference surface that is projected onto the concrete surface. The linear photo sensors detect the position where this laser plane intersects the surface, and through geometric calculation, the system determines the actual surface height relative to the laser plane. This intermediary approach allows inexpensive linear sensors to achieve precision comparable to more expensive direct measurement systems.
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
This solution enables reliable, accurate, and cost-effective autonomous concrete surface processing by providing precise height and tilt data for mapping and processing, improving efficiency and reducing manual intervention through self-locomotion control and integrated dust extraction.
Implementation Method 1
The control unit is arranged to detect a height of an incoming laser beam relative to the base plane, based on a point of incidence of the incoming laser beam on the linear photo sensor
Data Source
AI summary
A concrete surface processing machine (100) for processing a concrete surface, wherein the concrete surface processing machine is arranged to be supported on the concrete surface by one or more support elements (150) extending in a base plane (101) of the machine parallel to the concrete surface, wherein the concrete surface processing machine comprises a control unit (110) connected to at least one linear photo sensor (130) extending transversally to the base plane (101), and wherein the control unit (110) is arranged to detect a height (h) of an incoming laser beam (H) relative to the base plane (101), based on a point of incidence of the incoming laser beam (H) on the linear photo sensor (130).