Construction Robot Tolerance Compensation via Sensor Feedback
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Solution Overview
Problem
Existing mobile construction robotics systems fail to ensure compliance with permissible dimensional tolerances during automated laying or assembly of workpieces, as they do not regularly measure and adjust for actual dimensional deviations, leading to potential deviations from specified dimensions in construction plans.
Innovation Solution
A method utilizing a mobile construction robot with sensory detection of dimensional deviations, integrated processing, and adjustment of workpieces, where actual dimensions are determined using sensors and compared to nominal dimensions, allowing for real-time processing to ensure compliance with tolerances, involving a digital construction plan and control unit for decision-making on workpiece adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated laying systems simply line up objects without tolerance checking, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system performs preliminary measurement of actual workpiece dimensions before laying, and pre-calculates the tolerance chain impact. By measuring workpiece dimensions in advance and computing cumulative tolerance effects before execution, the system can proactively adjust positioning strategies to ensure final dimensional compliance without slowing down the automated laying process
Solution Approach 2:
The system implements a feedback loop where actual workpiece dimensions are measured, compared against nominal dimensions, and the deviation information is fed back to adjust subsequent laying operations. The electronic evaluation and control unit uses this feedback to dynamically modify positioning and selection of workpieces to maintain tolerance compliance throughout the construction process
2Ease of operation
If absolute position measuring systems are used for rough positioning, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The positioning process is segmented into two distinct stages: rough positioning using absolute position measuring systems for simplicity and speed, followed by fine positioning using relative measuring methods for precision. This segmentation allows each method to operate in its optimal performance range without compromise
Solution Approach 2:
The system performs preliminary rough positioning using absolute coordinates to establish approximate workpiece locations quickly, then performs subsequent fine adjustments based on actual measurements. This preliminary action enables the system to benefit from both coarse and fine positioning methods in sequence
3Productivity
If workpieces are not adjusted based on dimensional deviations, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system implements self-service by automatically measuring workpiece dimensions, evaluating tolerance compliance, and adjusting subsequent workpiece selection and positioning without human intervention. The electronic evaluation and control unit autonomously manages the entire tolerance compensation process, maintaining both productivity and precision
Solution Approach 2:
The system dynamically changes positioning parameters and workpiece selection based on measured dimensional deviations. By adjusting positioning coordinates, selection criteria, and layout parameters in real-time according to actual workpiece dimensions, the system maintains tolerance compliance without requiring physical workpiece modification, thus preserving productivity
Data Source
AI summary
The method involves an electronic evaluation and control unit being used to store a digital blueprint or a digital construction object model containing nominal dimensions and dimensional tolerances of the respective construction object, and, therein, at least those external dimensions of workpieces that are relevant to the respective construction object. At least one sensor is used to determine the current actual dimensions of the respective construction project and to supply them to the electronic evaluation and control unit. A construction robot is used to search for a workpiece that is to be used subsequently. After this workpiece has been found, the external dimensions of the workpiece that are relevant to the construction process are determined and are used to calculate dimensional deviations, and these are used to decide whether the respective workpiece is laid and/or installed at a position corresponding to the construction project model or is prepared to begin with such that its external dimensions after being laid and/or placed at the respective position are within dimensional tolerances.