Robotic Mesh Generation With Roll Spot Welding for Curved Reinforcement
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Solution Overview
Problem
Current robotic systems for manufacturing reinforcement structures in construction are limited by their ability to produce only discrete, one-directional reinforcement, which restricts the complexity and curvature of mesh structures that can be created, failing to meet the increasing demand for automated, high-performance reinforcement in complex building structures.
Innovation Solution
A method utilizing a robotic end-effector tool with a welding unit and sensors to apply a continuous secondary mesh structure to a primary mesh structure through roll spot welding, allowing for the creation of complex, three-dimensional mesh structures with varied curvatures by continuously rolling the end-effector over the primary structure and controlling the welding process in real-time based on contact force measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discrete metal wires or rebars are used for secondary mesh structure, then the system can manufacture reinforcement structures, but the field of application is limited and reinforcement is only continuous in one direction
Solution Approach 1:
The patent changes the fundamental parameter of secondary mesh structure from discrete elements to continuous wire strand, enabling multi-directional reinforcement and complex curved geometries while maintaining robotic manufacturability through automated wire feeding and welding systems
Solution Approach 2:
The patent segments the welding process into sequential roll spot welding operations along the continuous wire strand, allowing the robotic system to manufacture complex mesh structures by progressively welding the secondary mesh to the primary mesh in controlled segments
2Extent of automation
If robotic systems use discrete elements in defined length, then automation is achieved, but reinforcement continuity is restricted to one direction
Solution Approach 1:
The patent implements continuity of useful action by feeding the wire strand continuously through the welding process without interruption or cutting, enabling the secondary mesh structure to be continuous in multiple directions and providing stable multi-directional reinforcement throughout the mesh structure
3Productivity
If planar rebar mats are processed by articulated arm robots, then assembly is automated, but complex mesh structures with curvatures cannot be manufactured
Solution Approach 1:
The patent applies dynamics by enabling the robotic end-effector to move freely in six degrees of freedom, allowing the system to adapt to and manufacture complex three-dimensional mesh structures with various curvatures and geometries while maintaining high automation and productivity
4Stability of the object's composition
If continuous wire strand is welded to primary mesh structure, then multi-directional reinforcement is achieved, but welding process complexity increases
Solution Approach 1:
The patent replaces complex multi-axis positioning and clamping mechanisms with a simplified roll spot welding system that uses the natural rolling motion of the wire strand and automated welding control, reducing mechanical complexity while achieving continuous multi-directional reinforcement through the welding unit's integrated sensors and actuators
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the generation of reinforced concrete structures with improved load transfer capabilities and reduced cycle times, as the continuous secondary mesh structure can be applied without cutting or clamping, allowing for more complex and curved designs that meet the demands of modern construction.
Implementation Method 1
applying a continuous or endless secondary mesh structure (e.g., a continuous metal wire strand) to the provided primary mesh structure—in particular continuously—by roll spot welding
Data Source
AI summary
In one aspect the invention relates to a mobile robotic end-effector tool for generating a mesh structure for use in reinforced concrete building systems. The tool comprises: —at least one robotic end-effector (EE), being movable in six degrees of freedom for applying an endless secondary mesh structure (2 ms) to the provided primary mesh structure (1 ms) continuously by roll spot welding, —wherein the at least one robotic end-effector (EE) further comprises: —a welding unit (W), in particular a resistance welding unit, configured for welding the secondary mesh structure (2 ms) to the primary mesh structure (1 ms) at predefined connection positions to generate cross-wire connections; —contact force sensors, configured for measuring the contact force of the robotic end-effector (EE), being applied to the primary mesh structure (1 ms) during rolling over the primary mesh structure (1 ms); —a processor (P) for closed loop control of the at least one robotic end-effector (EE) by means of control signals, wherein the control signals are generated at least in part in response to the measured contact force.