Robotic Mesh Surface Assembly With Closed-Loop Geometry Correction
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Solution Overview
Problem
Conventional 3D printing technologies are limited in fabricating objects that are geometrically consistent with their 3D models, especially when using low-grade materials, making them unsuitable for architectural-scale projects requiring high-performance materials like steel or carbon fiber.
Innovation Solution
A robotic assembly cell system that uses a positioning robot and a welding robot, coordinated by a control application, to assemble a mesh by selecting and positioning physical polygons based on a simulated mesh, tolerating fabrication inaccuracies through closed-loop control and updating the simulated mesh to match the physical mesh.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D printing is used to fabricate physical objects from 3D models, then the fabrication process is simple and uses low-grade materials, but the physical objects are inconsistent with the 3D model and cannot use high-performance materials
Solution Approach 1:
The physical object is divided into multiple polygons that are assembled separately by robotic manipulators. Each polygon can be fabricated independently with high precision, and then positioned and attached to form the complete mesh surface, ensuring geometric consistency with the 3D model while allowing use of high-performance materials
Solution Approach 2:
Conventional 3D printing is replaced with a robotic assembly system that uses positioning robots and welding robots to assemble pre-fabricated polygons. This substitution enables higher precision and compatibility with high-performance materials like steel and carbon fiber, while maintaining ease of manufacture through automated robotic operations
2Strength
If conventional 3D printing fabricates objects with low-grade materials, then the process is simple, but it cannot be used for architectural-scale projects requiring high-performance materials
Solution Approach 1:
The structure is segmented into multiple polygons that can be fabricated using high-performance materials. This segmentation allows the use of strong materials like steel and carbon fiber in architectural-scale projects while managing complexity through modular assembly of individual polygons by robotic systems
Solution Approach 2:
The system changes the fabrication approach from monolithic 3D printing to modular polygon assembly. This parameter change enables the use of high-performance materials by fabricating each polygon separately with precise control over material properties and assembly parameters, making architectural-scale projects feasible
3Manufacturing precision
If robotic assembly is used to assemble physical polygons into a mesh, then geometric consistency with the simulated mesh is achieved, but the system complexity increases
Solution Approach 1:
The control application implements feedback by detecting the actual position of each physical polygon and comparing it with the simulated mesh. When deviations are detected, the system automatically adjusts the positioning and attachment process to maintain geometric consistency, managing the complexity of the robotic assembly cell through intelligent control
Solution Approach 2:
The system performs self-correction by automatically detecting and compensating for positioning deviations during assembly. The control application monitors the assembly process in real-time and adjusts operations to maintain geometric consistency with the simulated mesh, reducing the need for external intervention and managing system complexity
Data Source
AI summary
A robotic assembly cell is configured to generate a physical mesh of physical polygons based on a simulated mesh of simulated triangles. A control application configured to operate the assembly cell selects a simulated polygon in the simulated mesh and then causes a positioning robot in the cell to obtain a physical polygon that is similar to the simulated polygon. The positioning robot positions the polygon on the physical mesh, and a welding robot in the cell then welds the polygon to the mesh. The control application captures data that reflects how the physical polygon is actually positioned on the physical mesh, and then updates the simulated mesh to be geometrically consistent with the physical mesh. In doing so, the control application may execute a multi-objective solver to generate an updated simulated mesh that meets specific design criteria.