3D Robotic Concrete Printer Collision Prediction With Live Geometry Updates
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Solution Overview
Problem
Existing collision detection methods for 3D robotic concrete printers are inadequate, particularly in dynamic environments, leading to potential damage from unforeseen obstacles and worker interference during printing and post-processing.
Innovation Solution
A model-based collision prediction system that generates and updates a 3D collision model in real-time, integrating sensor data and predefined models to prevent collisions by comparing tool movements against the evolving concrete structure geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a-priori available geometries (global/static BIM data) are used for collision detection, then the collision detection system is simple to implement, but it cannot detect dynamic obstacles or changes in the construction environment
Solution Approach 1:
The patent combines multiple data sources (BIM data, sensor data from cameras, LIDAR, and other sensors) to create a unified 3D collision model that integrates both static and dynamic information about the construction environment, thereby improving detection accuracy without requiring a completely separate system
Solution Approach 2:
The patent introduces a 3D collision model as an intermediary representation that mediates between raw sensor data and collision detection decisions. This model serves as a dynamic digital twin of the construction environment, allowing the system to process and interpret complex sensor information efficiently
2Adaptability or versatility
If in-situ generated geometries (local/dynamic sensor data) are used for collision detection, then dynamic obstacles can be detected, but the system becomes complex and computationally intensive
Solution Approach 1:
The patent creates a universal 3D collision model that can represent multiple types of objects and environments using a unified data structure. This model can accommodate various sensor inputs (cameras, LIDAR, BIM data) and different construction scenarios, making the system highly adaptable without requiring separate processing pipelines for each sensor type
Solution Approach 2:
The system continuously updates the 3D collision model based on real-time sensor feedback and compares it with the planned toolpath. This closed-loop feedback mechanism allows the system to adapt to environmental changes dynamically while maintaining computational efficiency through incremental model updates
3Ease of operation
If workers manually control the extrusion tool for maintenance steps, then maintenance operations can be performed, but workers are at risk of accidentally colliding with freshly printed structures
Solution Approach 1:
The system provides self-service collision protection by automatically monitoring the tool's position relative to the printed structure using the 3D collision model. The system independently detects potential collisions and generates warnings or corrective actions without requiring external monitoring, enabling workers to perform maintenance safely
Solution Approach 2:
The system applies preliminary anti-action by predicting potential collisions before they occur during manual maintenance operations. The real-time collision detection continuously monitors the toolpath against the 3D collision model and prevents harmful actions by alerting workers or automatically adjusting the toolpath before contact with the printed structure can occur
4Productivity
If multiple independently generated print programs are executed simultaneously, then productivity increases, but the risk of collisions between different printing operations increases
Solution Approach 1:
The patent extends collision detection into the temporal dimension by tracking the 3D collision model across multiple time steps and different print programs. This four-dimensional approach (three spatial dimensions plus time) allows the system to detect and prevent collisions between simultaneously executing printing operations while maintaining high productivity
Data Source
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AI summary
The present invention concerns a system and a method for collision avoidance of a 3D robotic concrete printer, whereby the method comprises the steps of performing an application and/or manipulation process by executing instructions, such as based on G-Code, with a 3D robotic concrete printer by moving a tool in a path for applying and/or manipulating concrete material; and moving the tool in response to commands to a motion planner, said movement being assisted by a model-based collision prediction system, whereby the model-based collision-prediction system involves the steps of inferring and generating 3D geometries of concrete structures from applying and/or manipulating concrete structures by commanding the 3D robotic concrete printer, using the 3D geometries as a 3D collision model, which allow at any point in time to check if parts of the 3D robotic concrete printer would yield a collision when performing said movement; whereby the 3D collision model of the concrete structure is developed in parallel to the application and/or manipulation process and is updated in correspondence to the progress of the execution of the process instructions.