GB2514405A

GB2514405A - Robot for spraying insulation

Info

Publication number: GB2514405A
Application number: GB1309324.0A
Authority: GB
Inventors: Tomasz B Lipinski; Peter Rn Childs; Mathew Holloway
Original assignee: Q Bot Ltd
Current assignee: Q Bot Ltd
Priority date: 2013-05-23
Filing date: 2013-05-23
Publication date: 2014-11-26
Also published as: GB201309324D0

Abstract

A robot 1 for spraying insulation (such as polyurethane), comprising an elongate chassis 3 carrying a spray nozzle 4, a source 16 of spray thermal insulation foam coupled to the nozzle, and at least one wheel 2 mounted on the chassis arranged to drive the robot over a surface on which it is located. There may be a bearing surface 7 in the form of a hemisphere which is dragged over the surface over which the robot moves. The foam source may be a supply pipe and there may also be wires 15 to provide power to the robot. The robot is particularly suited for working in an underfloor cavity. Also claimed is a method of using such a robot.

Description

I

ROBOT FOR SPRAYING INSULATION

This invention relates to a robot for spraying insulation, and a method of using such a robot.

It is known to improve the thermal performance of buildings by insulating the wails (or, more generically, the external fabric or building envelope, such as walls, floor and roof) of those buildings. This can be currently achicvcd by fixing insulation boards or bats to walls or fitting these between joists and rafters. Spray insulation foam, such as Polyurethane is known, and can be sprayed onto the walls or roof structure in order to reduce the amount of heat that is transferred through the building fabric. In most cases, however, doing so is a labour intensive process, particularly when it is desired to insulate the cavity underneath the suspended wooden ground floor of many older (pre 1919) British (and European) solid brick houses. It can also be potentially hazardous due to the nature of the chemical processes involved in spraying the insulation and sharp building fixings and surfaces.

In such cases, the ground floor is formed of floorboards supported by joists, and the cavity below the floorboards is designed to remove ground moisture, gases and prolong the life of the timber floor, but remains a ventilated but otherwise unused void, typically occupied by building debris, wiring and the like. However, heat can escape from the ground floor rooms, through the void and then through the external walls and ventilation openings.

It is therefore desirable to insulate the floor whilst retaining such voids, but doing so is a labour intensive and awkward task, not merely due to the technical requirements to spray insulation within such a cavity, but also to lift the floorings and the possessions of the occupants of the buildings which would otherwise have been resting on the floor. This is inefficient, given that this will usually mean moving the occupants of such a house out of their dwelling (and removing furniture, destroying carpets, floor boards, generating waste and associated strife) whilst the insulation is applied.

According to a first aspect of the invention, we provide a robot for spraying insulation, comprising: a chassis carrying a spray nozzle; a source of spray thermal insulation coupled to the nozzle; and a propulsion system mounted on the chassis arranged to drive the robot over a surface on which it is located.

Thus, we present a robot that can be used to apply thermal insulation to locations such as under-floor cavities, thus providing a new way in which such insulation can be provided. In particular, the robot may advantageously be used to spray insulation in awkward cavities where manual spraying would have been difficult or inconvenient, or where access is difficult.

The robot may be sized so as to fit in an underfloor cavity. As such, the robot may be fit within a 25 cm by 15 cm by 50 cm cuboid. This allows access into more confined spaces that would have conveniently been possible with manual spraying.

The source of spray thermal insulation may be a port to which a supply pipe carrying the insulation can be fitted. Alternatively or additionally, the source may comprise a container carried on the chassis.

The propulsion system may comprise at least one wheel. Each wheel may be mounted so as to have two positions relative to the chassis, the chassis having a length: a first position where each wheel is positioned so as to be able to drive the robot along the length of the chassis and a second position where each wheel are aligned with the length, in which thc maximum cross-sectional area of the robot in a plane perpendicular to the length is less in the second position than in the first position.

Alternatively or additionally to comprising at least one wheel, the propulsion system may comprise at least one tiexible driven track, or a plurality of legs arranged to drive the robot over the surface.

Thus, this allows for an insulation-spraying robot which having a configuration in which the overall cross sectional area is reduced. This allows the robot to be introduced into spaces through a confined opening. In the case where the opening is specially made in order to introduce the robot into the space to be sprayed, this reduces the size of the opening required.

As such, a new method of working can be provided for applying underfloor insulation.

An opening can be made in the wall surrounding the underfloor cavity (typically an exterior wall) and the robot can be introduced, typically with the wheels in the second position. The wheels can then be moved into the first position so as to move the robot around the underfloor cavity, spraying insulation as appropriate.

Where we refer to "aligned" with respect to each wheel, we will typically mean that the wheel has an axis of rotation, which will be parallel with the length in the second position. Furthermore, where there are a plurality of wheels, such as the typical situation where there are a pair of wheels, the axes of rotation of each wheel may be coaxial in the second position as well as being parallel to the length of the chassis.

In the first position, the axis of rotation of each wheel may be generally perpendicular to the length of the chassis, so that rotation of each rheel drives the chassis along its length. However, each wheel may also be steerable over a predetermined range (which may be less than 180 degree, and typically less than 135 or 90 degrees) in order to steer the robot.

There may be a pair of wheels. The pair of wheels may be mounted on a wheel mounting member, with the wheel mounting member spacing the wheels apart. The wheel mounting member may be pivotally mounted on the chassis, rotation of the wheel mounting member relative to the chassis causing the wheels to move between the first and second positions. The wheel spacing member may be positioned perpendicular to the length in the first position and parallel, and typically along, the length in the second position.

The maximum cross section of the chassis in the second position may be that of each wheel, potentially plus a margin of less than 50mm, and preferably less than 20mm.

Thus, in the second position, the chassis and/or the remainder of the robot excluding each wheel and the chassis may fit within the cross section of each wheel, possibly plus the margin.

The nozzle may be mounted on the chassis through a movable arnz which allows the angle of the nozzle relative to the chassis to be varied. As such, the nozzle may therefore be able to aim at a variety of directions relative to the chassis. The moveable arm may be pivotable about at least two non-parallel, and preferably perpendicular, axes. It may be pivotable about an axis perpendicular to the length of Ihc chassis and/or an axis along thc length of thc chassis.

Thc robot may bc providcd with furthcr undrivcn whccls arrangcd to support thc chassis above a surface. However, as an alternative, thc robot may be provided with a bearing surface on its underside, typically on the chassis, which is dragged along the surfacc as thc wheels drivc thc chassis. The bcaring surface may be curved, such as part-spherically, in order to negotiate uncven surfaces. This allows a lower-profile robot to be provided, as it is not necessary to provide a second set of wheels which could potentially increase the cross-section of the robot.

The robot may be provided with a tail, which extends away from the robot at an end of the chassis distal from the wheels along the length. The tail may be connected to the chassis through a clutch, which pcrmits rotalion of lhc tail about thc chassis about a first axis (typically horizontal) perpendicular to the length and parallel to the axis of rotation of each wheel in tile first position but restricts rotation of the tail about the chassis about a second axis (typically vertical) perpendicular to the length and the first axis.

The tail may also provide a connection for the supply pipe, and typically will comprise the supply pipe itself Such supply pipes tend to be heavy, semi-rigid and an obstacle to movement or agility. However, by providing the clutch, we can make use of the otherwise disadvantageous features of the supply pipe. The tail can be used for balance, support and grounding, so that a second set of wheels are not needed. The clutch allows the robot to reverse easily while looping the hose sideways.

The robot may comprise a receiver for receiving command signals to control at least one of its motion and its spraying activity. This may be a wireless receiver for receiving signals wirelessly, such as a radio receiver, or may comprise a wired receiver, arranged to receive signals over a wired connection. The wired connection may form part of the tail.

Each wheel may comprise a tyre surrounding a motor arranged to drive the tyre. This reduces the need for external gearboxes or so on and as such provides for a lower profile. The outer surface of each tyre may be provided with protrusions such as spikes or bumps for improved traction.

According to a second aspect of the invention, there is provided a method of spraying thermal insulation into a cavity, thc method comprising introducing the robot of the first aspect of the invention into the cavity and causing it to spray the insulation through the nozzle onto at least one internal wall of the cavity.

Thus, we present a method of using the robot of the first aspect of the invention to insulate a cavity, in particular a cavity such as an underfloor cavity, with an internal wall including the underside of a suspended timber floor in an under-floor cavity.

The cavity will typically be an underfloor cavity, typically an underfloor cavity below floorboards of a suspended ground floor of a brick-built domestic dwelling. Such dwellings present a particular problem to insulate, cspecially those built a significant time ago (pre 1919) before the importance of insulation was appreciated.

The robot may be introduced into the cavity through a hole in one of the walls of the cavity. The hole may be larger than the maximum cross sectional area of the robot in the second position but smaller than the maximum cross sectional area of the robot in the first position, the cross sectional areas being taken along a plane perpendicular to the length. The method may comprise the step of making the hole in the wall prior to introducing the robot.

The method may comprise mapping the cavity before spraying the insulation. The step of mapping may comprise determining the positions of the internal walls to be sprayed, and may comprise determining the perimeter of the cavity, total height, obstructions, cabling, leaks and other issues, typically in order to prepare for access.

Whilst this may be done with the robot, the step of mapping the cavity may be carried out before the robot is introduced into the cavity. As such, the step of mapping may comprise the step of introducing a mapping apparatus, such as a mapping robot into the cavity. The mapping robot may be provided with at least one sensor for sensing the position of the walls to be sprayed and potentially other obstacles.

The method may further comprise the step of determining a path for the robot to traverse the cavity so as to spray the walls. This path may be transmitted to the robot (typically using the receiver) so that, when the robot is introduced into the cavity, it follows the path. The path may also include instructions for the positioning of the nozzle relative to the chassis for each position along the path.

For all of the aspects of the invention, examples of suitable thermal insulation include foam insulation, such as polyurethane foams.

There now follows, by way of example only, description of embodiments of the invention, described with reference to the accompanying drawings, in which: Figure 1 shows a side elevation of a robot for spraying thermal insulation foam in accordance with a first embodiment of the invention; Figure 2 shows a plan view of the robot of Figure 1; Figure 3 shows an underside plan view of the robot of Figure 1; Figure 4 shows a front elevation of the robot of Figure 1; Figures 5 aild 6 show rcar elevations of the robot of Figure 1, with thc spraying arm in different positions; Figure 7 shows a cross section through the wheels of the robot of Figure I; Figures 8 to 10 show sidc clcvations of the robot of Figure 1, with thc spraying arm at different elevations; Figure 11 shows a perspective view of a thermal insulation spraying robot in accordance with a second embodiment of the invention, in a first position; Figure 12 shows a perspective view of the robot of Figure 11 in a second position Figure 13 shows a schematic cross section through a house that is to have a cavity insulated in accordance with a method in accordance with a further embodiment of the invention; Figure 14 shows an enlarged cross section through the cavity of the house of Figure 13; and Figure 15 shows a perspective view of the inside of the cavity.

Figures 1 to 10 of the accompanying drawings show a robot I that can be used to spray thermal insulation foam (such as polyurethane). The robot 1 comprises a pair of wheels 2 mounted at the front end of an elongate chassis 3. The chassis has a long axis 6 running from the front end 3a of the chassis 3 towards the rear 3b. At the rear 3b of the chassis 3, there is provided a hemispherical shell 7; this provides a bearing surface which is dragged over the surface under the robot (and so removes the need to provide further wheels at the rear of thc chassis 3).

The chassis 3 also supports a spray nozzle 4 mounted on the chassis 3 through a spray arm 5. The spray arm allows both the angle of elevation of the spray nozzle to be varied (as shown in Figures 8 to 10 of the accompanying drawings) and the azimuthal angle of the spray nozzle to be varied (as shown in Figures 5 and 6 of the accompanying drawings). The movement in both directions is caused by actuators 8, 9. Thus, the spray nozzle 4 can be pointed in any direction over a substantial solid angle above the robot 1, and so the robot I can be used to spray a large area surrounding itself.

In order to mount the wheels 2 on the chassis 3 and to drive the wheels, each wheel 2 is provided with a motor 10 mounted on the chassis 3. An output shaft 11 of each motor 10 engages a hub 12 of the respective wheel 2. Thus, the motors 10 not only directly drive each wheel 2, but they provide the support for the wheels 2 without any intervening drive train. This reduces weight and complexity, and also is efficient use of space as the motors 10 are housed within the wheels 2.

The wheels 2 can therefore rotate with the output shafts 11 about a horizontal axis perpendicular to the length 6. The direction of travel of the robot 1 can be controlled by controlling the relative rotational speeds of the wheels 2. Spikes 16 on the wheels improve traction and allow the wheels 2 to overcome obstacles that might be cncountered.

The robot I is also provided with a tail 13, which is mounted at the rear 3b of the chassis close to the centre of the hemispherical shell 7. The tail 13 is mounted on the chassis 3 through a clutch 14. It also provides a connection for wires 15 which provide power and control signalling for the motors 10 and actuators 8, 9, and a source of the insulation foam to be sprayed, by means of supply pipe 16.

Supply pipe 16 is heavy, semi-rigid and an obstacle to movement or agility. We have been able to employ its shortcomings for our benefit, as it is used as balance, support and grounding, so that a second set of wheels is not necessary. The clutch 14 allows the robot to reverse easily while looping' the hose sideways (therefore not pushing it into the wall etc) in one instance, have a rigid straight tail in another (while trying to keep a straight line forward) or drag excess hose into a smaller cavity to avoid catching the sleeper %vall or an obstacle.

In order to ioop the supply pipe 16, the robot is reversed using one wheel 2 into the tail 13, clutch 14 loose. The clutch 14 is then locked and the wheels 2 driven so as to straighten up the robot. This gives about a meter of hose looped to one side of the robot. The clutch can again be released and the robot moved forward, leaving most of the cable stationary until it tightens. This works very well in localised spraying or positioning in preference to dragging the whole 8-1 Oni of the heavy hose.

It can be seen that the chassis 3, the spray arm 5 and nozzle 4 when aligned flat against the chassis 3 and the actuators 8, 9 all fit within the cross section of the wheels 2. Thus, the robot 1 is of relatively low profile, and so can move around a cavity into which a human operator would not be able to fit. As such, this means that cavities such as underfloor cavities can be insulated much less intrusively -in the underfloor cavity example, there is no longer any need to lift all of the floorboards in a room, merely enough to allow access to the robot into the cavity.

A robot 51 in accordance with a second embodiment of the invention is shown in Figures 11 and 12 of the accompanying drawings. Equivalent features to those of the first embodiment have been indicated with corresponding reference numerals, raised bySO.

In this embodiment, rather than being mounted for rotation relative to the chassis 53, the wheels 52 are mounted on a wheel mounting member 70, which is pivotally mounted on the chassis 53. This means that the wheels can be positioned in two positions, shown in Figures 11 and 12 respectively.

In the first position, shown in Figure 11 of the accompanying drawings, the common axis of rotation 71 of the wheels is horizontal and perpendicular to the length 56 of the chassis 53. The wheels 52 function as described above with reference to the first cmbodiment of the invention to drive thc robot 51.

In the second position, shown in Figure 12 of the accompanying drawing, the wheel mounting member 70 has rotated relative to the chassis 53 (either through the action of an actuator within the wheel mounting member 70 or by unlocking the mounting member 70 relative to the chassis 53 and driving wheels 52 in opposite directions) about an vertical axis. Accordingly, the axis of rotation 71 of the wheels 52 is now aligned parallel with the length 56 of the chassis 53. The maximum cross section of the robot 51 in any plane perpendicular to the length 53 is reduced with respect to the first embodiment of the invention.

The robot 51 may also be provided with a manipulator arm, which allows the robot to lift or push wires and other moveable hazards, particularly suspended ones, out of its way (and possibly secure them to the floor). This can be a simple rigid arm mounted pivotally on the chassis 53 and having an actuator to control its movement. It may be provided with a hook or a fork at the end distal from the chassis 53. Alternatively, this could be carried out by the spray arm 5, which could be used to lift hazards out of the way of the robot.

The use of the robots 1, 51 of the two embodiments described above can be demonstrated in accordance with Figures 13 to 15 of the accompanying drawings.

Whilst we will refer to the robot 51 of the second embodiment of the invention, the robot 1 of the first aspect of the invention could be used in its place.

Figure 13 shows a house having two storeys 100, 101 and an underfloor cavity 102 beneath the lower floor 100. It is desired to insulate the walls 103, 104 of the cavity 102 in order to improve the thermal performance of the house. The upper walls 104 are a suspended wooden floor formed of wooden floorboards supported on joists.

The cavity is generally of the order of 20-50 cm high, and so is tricky to access.

Furthermore, as seen in Figure 15 of the accompanying drawings, debris 105, wires 107 and protruding brickwork 106 all make movement within the cavity difficult. The following method, in accordance with a further embodiment of the invention, may make the act of insulating such cavities (much) easier, quicker and more cost effective.

In the first step, access is allowed into the cavity for a mapping robot 110. This can be by making a hole 111 in a wall 103 of the cavity 102. In this embodiment, the hole 111 is in an cxtcrior wall 103, which has thc advantage that it is not necessary to disturb the occupant of the house (with the consequent removal of floors, carpets etc).

Alternatively, sufficient floorboards can be raised to allow the mapping robot access 110. This will generally be significantly fewer than would be required to gain access to the entire cavity by a human user.

The mapping robot 110 is similar in function to the robot 51 discussed above, but instead of carrying a spray arm 55 and nozzle 54, it carries a camera and/or other sensing apparatus (such as an infrared camera, sonar or lidar apparatus and the like).

The mapping robot traverses the cavity 102, mapping out the position of hazards (such as those lOS, 106, 107 discussed above) and the general layout of the cavity. The mapping robot 110 is then retrieved through the opening 110 through which it entered the cavity 102.

Use of an infrared camera is advantageous, as, as well as mapping the cavity, the state of any wiring can be inspected to ensure that there is no wiring that is overheating and as such requiring replacement.

The resultant map of the cavity is analysed to generate a path for the spraying robot 51. The path includes a track of positions for the robot 51 to occupy, plus information as to the correct aiming of the spray nozzle 54. Typically, the path will involve the robot 51 moving to the furthest point from the point of entry, and then spraying the internal walls 103, 04 of the cavity, backing out of the cavity as it does so.

Thc robot 51 is thcn introduccd into the cavity, typically through thc hole 110. The robot 51 can be introduced in the second position, so that it is of relatively low profile. This means that the hole 110 can be smaller than otherwise be the case, as it only needs to be big enough for the robot 54 in the second position (and not the first position) to pass through (approximately 18 centimetres in diameter).

Once through the hole 110, the robot 54 reverts to the first position and commences spraying in accordance with the path. It will make its way gradually back towards the hole 110 and, once the suspended timber floor 104 has been appropriately sprayed, will be retrieved through the hole 110.

Thus, spraying of the cavity can be achieved without having to lift any of the floorboards, and without even disturbing the occupants of the house. This is particularly helpful for landlords with housing stock that comprises numerous older properties.

The robot 1 of the first embodiment can be used in this method: rather than making the hole 110, the robot 1 would typically be installed and retrieved by lifting sufficient floorboards to allow access to the robot. This would only be a few floorboards, typically much fewer than would be required to allow a hunian operative access.

Claims

CL Al NI S 1. A robot for spraying insulation, comprising: a chassis carrying a spray nozzle; a source of spray thermal insulation coupled to the nozzle; and a propulsion system mounted on thc chassis arranged to drive lhc robot over a surface on which it is located.
2. The robot of claim 1, sized so as to fit in an underfloor cavity.
3. The robot of claim 1 or claim 2, sized so as to fit within a 25 cm by 15 cm by cm cuboid.
4. The robot of any preceding claim, in which the propulsion system comprises at least one drivcn whecl.
5. The robot of any claim 4, in which each wheel is mounted so as to have two positions relative to the chassis, the chassis having a length: a first position where each wheel is positioned so as to bc ablc to drive the robot along the length of the chassis and a second position where each wheel is aligned with the length, in which thc maximum cross-sectional area of the robot in a plane perpendicular to the length is less in the second position than in the first position.
6. The robot of claim 5, in which there are a pair of wheels mounted on a wheel mounting member, with the wheel mounting member spacing the wheels apart and the wheel mounting member being pivotally mounted on the chassis, rotation of the wheel mounting member relative to the chassis causing the wheels to move between the first and second positions.
7. The robot of any of claims 4 to 6, in which the cross section of the chassis is at most that of each wheel.
S. The robot of any of claims 4 to 7, provided with further undriven wheels arranged to support the chassis above a surface.
9. The robot of any of claims 4 to 8, in which each wheel comprises a tyre surrounding a motor arranged to drive the tyre.
10. The robot of claim 9, in which an outer surface of each lyre is provided with protrusions.
11. The robot of any preceding claim, provided with a bearing surface on its underside which is dragged along a surface on which the robot is positioned as the propulsion system drives the chassis.
12. The robot of claim 11, in which the bearing surface is curved.
13. The robot of any preccding claim, in which the nozzle is mounted on the chassis through a movable arm, which allows the angle of the nozzle relative to the chassis to be varied.
14. The robot of any preceding claim, comprising a tail which extends away from the robot at an end of the chassis distal from the wheels along the length, the tail being connected to the chassis through a clutch which permits rotation of the tail about the chassis about a first axis perpendicular to the length and parallel to the axis of rotation of each wheel in the first position but selectively restricts rotation of the tail about the chassis about a second axis perpendicular to the length and the first axis.
15. The robot of claim 14, in which the source of spray thermal insulation is a port in the tail, the tail further comprising a supply pipe carrying the insulation fitted to the port.
16. A method of spraying thermal insulation into a cavity, the method comprising introducing a robot in accordance with any preceding claim into the cavity and causing the robot to spray the insulation through the nozzle onto suspended timber floors of the cavity.
17. The method of claim 16, in which the cavity is an underfloor cavity.
18. The method of claim 16 or claim 17, in which the robot is introduced into the cavity through a hole in one of the walls of the cavity.
19. The method of claim 8, comprising the step of making the hole in the wall prior to introducing the robot.
20. The method of any of claims 16 to 19, comprising mapping the cavity before spraying the insulation.
21. The method of claim 20, in which the step of mapping may comprise the step of introducing a mapping apparatus, such as a mapping robot, into the cavity.
22. The method of claim 21, in which the mapping robot is provided with at least one sensor for sensing the position of the walls to be sprayed and potentially other o b st ac I es.
23. The method of any of claims 20 to 22, comprising the step of determining a path for the robot to traversc the cavity so as to spray the walls.
24. The method of claim 23, in which the path also includes instructions for the positioning of the nozzle relative to the chassis for each position along the path.
25. A robot for spraying insulation substantially as described herein with reference to and as illustrated in Figures 1 to 10 or Figures 11 and 12 of the accompanying drawings.
26. A method of spraying insulation on the internal walls of a cavity substantially as described herein with reference to and as illustrated in Figures 13 to 15 of the accompanying drawings.