Robotic Production Cells for Mass-Customized Prefab Buildings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The building industry faces challenges in workforce shortages, increased 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 (BIMs) to automate the manufacturing process, including sorting production cells and assigning tasks and tools, enabling the automated fabrication of prefabricated building components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cement-based construction methods are used, then construction processes are simple and familiar, but labor costs increase, productivity decreases, and environmental impact worsens
Solution Approach 1:
The patent replaces conventional mechanical construction processes with automated robotic systems. Robots equipped with specialized end effectors perform cutting, drilling, fastening, and assembly operations that were traditionally done manually or with simple mechanical tools, thereby increasing productivity while managing complexity through automation
Solution Approach 2:
The patent changes the physical and chemical parameters of construction materials by using engineered wood products (CLT, GLT, LVL) instead of conventional cement-based materials. This substitution improves productivity and reduces environmental impact while requiring new manufacturing parameters and processes that are managed through the integrated software system
2Extent of automation
If automated robotic production is implemented, then labor costs reduce and productivity increases, but device complexity and integration challenges increase
Solution Approach 1:
The patent employs universal robotic platforms that can perform multiple construction tasks through interchangeable end effectors. The same robotic base unit can be configured for cutting, drilling, fastening, or assembly operations, reducing overall system complexity while maintaining high automation levels across different manufacturing operations
Solution Approach 2:
The patent introduces an integrated software system as an intermediary that coordinates between BIM models, production planning, robotic control, and quality assurance. This software layer manages the complexity of integrating multiple robotic systems and processes by providing a unified control interface and data management platform
3Productivity
If mass production of prefabricated buildings is achieved, then productivity increases and labor costs reduce, but adaptability to customize designs decreases
Solution Approach 1:
The patent performs preliminary digital modeling and production planning using BIM technology before physical manufacturing begins. All design customizations are resolved in the digital domain, allowing mass production of customized designs without sacrificing adaptability. The software system locks in design parameters early, enabling efficient automated production while maintaining design flexibility
Solution Approach 2:
The patent implements dynamic reconfiguration capabilities in the manufacturing system, allowing production parameters, robotic toolpaths, and assembly sequences to be adjusted based on specific design requirements. This dynamic adaptability enables the system to handle customized designs while maintaining mass production efficiency through automated parameter adjustment
4Manufacturing precision
If integrated approaches for mechanical, electrical, and plumbing elements are implemented, then manufacturing precision improves, but device complexity and difficulty of integration increase
Solution Approach 1:
The patent segments the integration of mechanical, electrical, and plumbing elements into distinct modular operations. Each system is installed and integrated separately through specialized robotic end effectors, allowing precise control of each integration process while managing overall complexity through modular assembly sequences coordinated by the software system
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.