Concrete Surface Mapping Robot for Defect Detection and Process Planning
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Solution Overview
Problem
Current concrete surface processing technologies lack efficient and cost-effective methods for autonomous mapping and inspection, particularly in determining surface quality and planning processing operations, as existing solutions do not fully address the challenges of detecting small defects and varying surface conditions.
Innovation Solution
A concrete surface processing machine equipped with self-locomotion, a control unit, and multiple surface quality sensors including 3D cameras, radar sensors, laser scanners, and gloss sensors, which can acquire high-resolution images and data to assess surface quality, detect defects, and adapt to different surface types, enabling autonomous inspection and planning of processing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple surface quality sensors including 3D cameras are used to detect small defects and assess surface quality, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple different types of surface quality sensors (3D camera sensors, radar sensors, laser scanners, gloss sensors) into a single integrated sensor arrangement on the concrete surface processing machine. This merging approach allows the system to detect various surface defects and qualities simultaneously, improving measurement precision while managing device complexity through unified integration.
Solution Approach 2:
The sensor arrangement is designed to perform multiple functions: 3D camera sensors detect scratch marks and cracks, radar sensors assess surface quality, laser scanners measure surface topology, and gloss sensors evaluate surface finish. This multi-functional sensor system enables comprehensive surface inspection across different defect types and quality parameters, resolving the contradiction between precision and complexity.
2Measurement precision
If high resolution 3D camera sensors are positioned close to the concrete surface to detect small defects, then measurement precision is improved, but the machine complexity increases
Solution Approach 1:
The 3D camera sensors are positioned at specific locations on the machine (front, rear, left, and right sides) to capture surface quality data from different perspectives and locations. This localized positioning strategy ensures high-resolution defect detection while managing the complexity of sensor arrangement through systematic placement rather than random or overly complex configurations.
3Productivity
If autonomous surface inspection and mapping is implemented to improve processing efficiency, then productivity is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary surface inspection and mapping operations before the actual concrete surface processing. The sensor arrangement captures surface quality data, creates maps of the concrete surface, and identifies defects in advance, allowing the processing machine to plan and optimize its processing path and parameters, thereby improving productivity while managing complexity through sequential operation.
Solution Approach 2:
The autonomous control system uses feedback from the sensor arrangement to continuously monitor surface quality, adjust processing parameters, and navigate the machine. The control unit receives data from multiple sensors, processes this information, and makes real-time adjustments to maintain optimal processing conditions, resolving the contradiction between productivity and control complexity.
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
The machine effectively inspects concrete surfaces for defects, determines surface quality, and plans processing operations, ensuring efficient and accurate concrete surface preparation by providing detailed quality assessments and tool selection support, thereby improving processing efficiency and outcome.
Implementation Method 1
The one or more surface quality sensors comprise a three-dimensional (3D) camera sensor arranged to acquire a three-dimensional high resolution representation of the concrete surface
Implementation Method 2
The 3D camera is advantageously combined with a system of light sources that can be controlled from a control unit, in order to perform a surface-from-shadow (SFS) or a surface-from-shading procedure to determine a 3D structure of the surface
Implementation Method 3
The one or more surface quality sensors also comprises a radar sensor
Implementation Method 4
The one or more surface quality sensors comprises a laser scanner
Implementation Method 5
The one or more surface quality sensors comprises a gloss sensor
Implementation Method 6
the control unit is arranged to compensate an output signal from the radar sensor for vibration in the machine based on an output signal from the IMU
Data Source
AI summary
A concrete surface processing machine (100) for processing a concrete surface, wherein the machine comprises means for self-locomotion and a control unit (110) arranged to control the means for self-locomotion, wherein the machine comprises one or more surface quality sensors connected to the control unit (110) and arranged to determine a local surface quality of the concrete surface, and wherein the control unit (110) is arranged to control a self-locomotion of the machine to determine a plurality of local surface quality values associated with respective different locations on the concrete surface.