Autonomous Tile Grouter With Edge-Angle Nozzle and Sponge Belt
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Solution Overview
Problem
Existing automated systems for grouting tiles are inefficient and lack versatility, particularly when dealing with a variety of tile sizes, shapes, and geometrical configurations, and are not effective in diverse lighting and environmental conditions.
Innovation Solution
An autonomous grouting robotic apparatus equipped with a grout cleaning arrangement, grout extruder, power and drive systems, and a control system that uses LIDAR, imaging sensors, and motion sensors to map and identify grouting lines, dispense grout, and clean excess grout, with adjustable nozzles and sponge belts for precise alignment and edge handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual grouting tools (trowel or grout float) are used, then the grouter can handle various tile configurations and environments, but the process is laborious and inefficient
Solution Approach 1:
The robotic grouter integrates multiple functions into a single system: grout extrusion through the nozzle, excess grout removal via the sponge belt, and belt cleaning through the cleaning assembly. This multi-functional design allows the robot to handle various tile configurations and environments autonomously, matching the versatility of human grouters while eliminating manual labor.
Solution Approach 2:
The sponge belt automatically cleans excess grout from tiles as the robot moves forward, and the cleaning assembly continuously cleans the sponge belt itself. This self-service mechanism eliminates the need for separate manual cleaning operations, maintaining versatility across different tile layouts while significantly improving grouting efficiency.
2Extent of automation
If automated robotic systems are used, then labor is reduced, but the system is less versatile than human grouters in handling different tile sizes, shapes, and configurations
Solution Approach 1:
The robotic grouter features dynamic adjustments including variable speed control of the grout extrusion motor and sponge belt motor, adjustable sponge belt tension through the cleaning assembly, and programmable motion paths. These dynamic capabilities allow the automated system to adapt to different tile sizes, shapes, and geometrical configurations, matching human grouter versatility while maintaining high automation levels.
3Manufacturing precision
If grout is extruded into gaps, then tiles are grouted, but excess grout must be cleaned off tiles carefully to avoid disrupting the grout between tiles
Solution Approach 1:
The patent combines the grout extrusion function and the cleaning function into a single integrated robotic system. The sponge belt is positioned to simultaneously remove excess grout while the nozzle deposits grout into gaps. This merging of functions maintains precise grout placement while simplifying the overall process compared to separate manual operations, reducing the complexity of coordinating multiple independent actions.
Solution Approach 2:
The sponge belt acts as an intermediary between the grout extrusion process and the tile surface. It continuously removes excess grout in a controlled manner, preventing grout from hardening on tiles while avoiding disruption to the grout between tiles. This intermediary mechanism enables precise grout placement without requiring complex separate cleaning operations.
4Productivity
If existing automated tools are used for specific tasks, then those tasks are performed efficiently, but they cannot handle edge grouting or work in diverse environments
Solution Approach 1:
The robotic grouter is designed as a universal system that can perform grouting in diverse environments including edge areas, corners, and various tile configurations. The integrated design with adjustable parameters and programmable paths allows it to efficiently execute multiple task types that would require different specialized tools, maintaining high productivity across all applications.
Data Source
AI summary
An autonomous grouting robotic apparatus comprising a sponge belt, a front sponge guide assembly, a grout extruder with a nozzle, cameras, and a LIDAR is configured to map a room and identify grouting lines each corresponding to a gap between tiles and to drive the robot and control extrusion of the grout from the nozzle and to clean excess grout off tiles. The front sponge guide assembly and grout extruder are mounted to the robotic apparatus using a pivoting mounting arrangement to control a tilt angle to allow extruding into grouting gaps located along the edges of the room.