Robotic Brick Laying System with Mason Guidance
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Solution Overview
Problem
Masonry construction is labor-intensive, costly, and prone to worker injuries and fatigue, with limited automation, leading to high labor costs and slow construction processes, which hinders the widespread use of brick structures despite their environmental benefits.
Innovation Solution
A robotically assisted brick laying system comprising a gantry with a moveable platform, a robotic arm assembly, a mortar applicator, and sensing and positioning components, allowing a mason to focus on craftsmanship while the robot handles repetitive tasks, such as precise mortar application and brick placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual brick laying is used, then craftsmanship and quality control are maintained, but labor costs are high and construction speed is slow
Solution Approach 1:
The brick laying process is segmented into distinct functions: the robotic arm handles mortar application and brick placement, while the mason focuses on pointing and finishing work. This division allows automation of repetitive tasks while preserving human craftsmanship for quality-critical operations.
Solution Approach 2:
The robotic arm serves as an intermediary between the mason and the brick laying process. It executes precise mortar application and brick placement based on mason guidance, bridging the gap between manual control and automated precision.
2Productivity
If more masons are hired to increase construction speed, then productivity improves, but labor costs increase and worker fatigue/injuries increase
Solution Approach 1:
The robotic arm performs the physically demanding tasks of mortar application and brick placement autonomously, serving itself to complete repetitive operations without human physical intervention. This eliminates worker fatigue and injury risks associated with these specific tasks.
Solution Approach 2:
The mechanical system of human masons performing repetitive mortar application and brick placement is replaced with an automated robotic arm. This substitution maintains or improves construction speed while eliminating the physical strain and injury risks faced by human workers.
3Loss of time
If traditional brick laying methods are used, then material handling is simple, but construction time is excessive and energy costs are high
Solution Approach 1:
The robotic arm applies precise amounts of mortar to each brick before placement, and the system pre-positions bricks for optimal placement. This preliminary preparation of materials and positioning accelerates the overall construction process significantly.
Solution Approach 2:
The robotic arm operates continuously without the breaks, fatigue, and coordination delays inherent in manual labor. The system maintains continuous productive action throughout the brick laying process, dramatically reducing total project completion time.
Data Source
AI summary
A brick laying system where an operator such as a mason works proximate a moveable platform having a robotic arm assembly, a mortar applicator with a mortar transfer device, and a brick transfer device to build structures. The robotically assisted brick laying system may also contain a stabilizer having a disturbance sensing and a disturbance correcting component that provides compensation for disturbances caused by load shifting, movement of the platform, wind, operator movement, and the like. In addition, the robotically assisted brick laying system has a sensing and positioning component for controlling placement of the moveable platform and robotic arm assembly. The interoperability of the system with a mason or skilled operator removes much of the manual labor component of brick laying, allowing the mason more time to focus on craftsmanship and quality, thus improving the end product and the overall working conditions of the mason.