Real-Time Evaluator for Prefab Retrofit Panel Installation
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Solution Overview
Problem
Conventional installation techniques for prefabricated panels lack real-time correction capabilities using laser-based technologies, leading to alignment issues and variances that affect the integrity of building envelopes, such as air and water barriers, resulting in increased rework and costs.
Innovation Solution
A system comprising a machine vision subsystem, a controller subsystem, and a user interface subsystem that uses as-built measurements from laser-based devices to provide real-time guidance for panel installation, tracking panel positions in six dimensions and issuing corrective instructions to ensure accurate placement within predetermined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional laser-based surveying tools are used for as-built measurements, then measurement capability is provided, but real-time correction during installation is not achieved
Solution Approach 1:
The system performs as-built measurements and creates a digital twin model before installation begins, preparing all correction data in advance so that real-time guidance can be provided during installation without delays
Solution Approach 2:
The system continuously tracks panel position during installation using machine vision and provides real-time feedback to the installer through a user interface, enabling immediate corrections rather than post-installation surveying
2Measurement precision
If conventional surveying methods are used after installation, then alignment errors are detected, but rework is required to correct variances
Solution Approach 1:
Real-time tracking and feedback provide continuous alignment verification during installation, allowing immediate correction of deviations without requiring post-installation surveying and rework
Solution Approach 2:
The system enables installers to self-correct alignment issues by providing real-time guidance through the user interface, eliminating the need for external surveying services and subsequent rework
3Manufacturing precision
If real-time tracking and corrective guidance systems are implemented, then installation accuracy is improved, but system complexity increases
Solution Approach 1:
A digital twin model serves as an intermediary between the physical panel and the control system, simplifying the tracking and guidance process by representing the panel's desired position and comparing it with actual position in real-time
Solution Approach 2:
The system integrates multiple functions into a single platform: as-built measurement, digital twin creation, real-time tracking, corrective calculation, and user guidance, reducing overall system complexity despite the advanced capabilities
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 system significantly reduces installation time and costs, enhances panel performance by improving alignment and reducing rework, and ensures higher quality installation of building envelopes by providing live guidance during the installation process.
Implementation Method 1
The targets can be mechanical clamp optical targets vacuum fixture optical targets, or essentially any other trackable target. The panel targets and façade targets can be retroreflectors and the machine vision subsystem can include a laser-beam source, a beam scanning module, and an imaging module capable of tracking the retroreflector targets.
Implementation Method 2
The machine vision subsystem can track motion of panel targets relative to façade targets as an overclad panel equipped with the panel targets is brought towards, and installed at, a predetermined location of the façade equipped with the façade targets.
Data Source
AI summary
A real-time evaluator decreases the cost of building envelope construction and retrofits by reducing the installation time for overclad panels and enhancing performance of the panels through higher installation quality. The real-time evaluator includes a machine vision subsystem to measure real-time locations of the panels as their being installed, a digital twin manager device to manage a current panel position digital twin based on the real-time measurements and make comparisons to a target panel position digital twin. The comparisons can be used to provide installation guidance to panel installers that can improve both the speed and accuracy of installation.