Robotic Cell Matrix for Custom Prefab Building Production
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Solution Overview
Problem
The building industry faces challenges in workforce shortages, high labor costs, construction safety, and environmental impact due to conventional cement-based construction methods, with a lack of computational design tools and automated construction solutions for prefabricated building production, particularly in integrating mechanical, electrical, and plumbing elements during manufacturing.
Innovation Solution
A mass customizable production system featuring configurable production cells with robotic units and a software system that generates a production matrix based on Building Information Models (BIM) to sequence and control robotic units for automated manufacturing of prefabricated building components, enabling efficient integration of various elements and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cement-based construction methods are used, then construction flexibility and customization are maintained, but labor costs increase, productivity decreases, and safety issues arise
Solution Approach 1:
The patent replaces manual mechanical construction processes with automated robotic systems. Robots equipped with specialized end effectors perform cutting, drilling, fastening, and assembly operations that were traditionally done by hand or with simple power tools, thereby increasing productivity while reducing labor dependency
Solution Approach 2:
The system enables self-service construction through automated material handling and processing. The robotic units autonomously navigate the construction site, locate components, retrieve materials, and perform assembly operations without continuous human intervention, allowing the construction process to serve itself
2Adaptability or versatility
If manual construction processes are used, then adaptability to design changes is maintained, but labor costs increase and workforce availability becomes a constraint
Solution Approach 1:
The robotic system incorporates dynamic reconfigurability through interchangeable end effectors and programmable control. The robots can adapt their tools and operations based on real-time construction requirements and design changes, maintaining versatility while operating at automated speeds
Solution Approach 2:
The system uses programmable parameters and digital models to accommodate design variations. By changing software parameters and robot trajectories rather than physical configurations, the system maintains adaptability to custom designs while preserving high productivity
3Productivity
If automated manufacturing is implemented, then labor costs are reduced and productivity increases, but integration of mechanical, electrical, and plumbing elements becomes more complex
Solution Approach 1:
The robotic platform is designed with multi-functionality, capable of performing mechanical, electrical, and plumbing operations through tool changes and programmable sequences. This universal robot reduces the need for multiple specialized machines, managing integration complexity while maintaining high productivity
Solution Approach 2:
The construction process is segmented into discrete operations (cutting, drilling, fastening, wiring, piping) that can be independently programmed and executed. This modular approach to task segmentation allows complex integration work to be broken down into manageable automated steps
4Speed
If prefabricated building components are produced, then construction speed increases, but integration of various elements during manufacturing becomes more difficult
Solution Approach 1:
Manual assembly operations in prefabrication are replaced with automated robotic drilling, fastening, and joining processes. This substitution maintains manufacturing ease by eliminating complex manual coordination while achieving high construction speeds through rapid automated production
Data Source
AI summary
An automated manufacturing system and method is provided. The system includes a software system and a production system. The software system includes a design module, an engineering module, and a manufacturing module for the design, engineering, and subsequent production of a prefabricated building product. The production system includes a matrix of cells and a plurality of robotic production units configurable with a plurality of production tools. The matrix includes a number of columns and a number of rows, each column representing a product to be worked on and each row representing a type of work to be performed on each product. The system processes a building model and configures each cell to perform specific work with one or more robotic production units and one or more production tools. A prefabricated building product is built in stages as it moves from cell to cell.