US20200094958A1 - Roof repair drone - Google Patents

Roof repair drone Download PDF

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Publication number
US20200094958A1
US20200094958A1 US16/140,048 US201816140048A US2020094958A1 US 20200094958 A1 US20200094958 A1 US 20200094958A1 US 201816140048 A US201816140048 A US 201816140048A US 2020094958 A1 US2020094958 A1 US 2020094958A1
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US
United States
Prior art keywords
membrane
communication unit
aerial drone
printer
roof
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/140,048
Other languages
English (en)
Inventor
Carl De LEON
Blaise LEEBER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sika Technology AG
Original Assignee
Sika Technology AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sika Technology AG filed Critical Sika Technology AG
Priority to US16/140,048 priority Critical patent/US20200094958A1/en
Assigned to SIKA TECHNOLOGY AG reassignment SIKA TECHNOLOGY AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DE LEON, CARL, LEEBER, BLAISE
Priority to JP2021514512A priority patent/JP7545387B2/ja
Priority to US17/265,676 priority patent/US20210300556A1/en
Priority to PCT/EP2019/075757 priority patent/WO2020064766A1/en
Priority to EP19774098.8A priority patent/EP3856632A1/en
Priority to CN201980059891.9A priority patent/CN112739620A/zh
Publication of US20200094958A1 publication Critical patent/US20200094958A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C39/00—Aircraft not otherwise provided for
    • B64C39/02—Aircraft not otherwise provided for characterised by special use
    • B64C39/024—Aircraft not otherwise provided for characterised by special use of the remote controlled vehicle type, i.e. RPV
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/02—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using liquid or paste-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24—Apparatus or accessories not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G23/00—Working measures on existing buildings
    • E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
    • E04G23/0281—Repairing or restoring roofing or roof covering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B64C2201/127—
    • B64C2201/141—
    • B64C2201/146—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
    • B64U2101/00—UAVs specially adapted for particular uses or applications
    • B64U2101/25—UAVs specially adapted for particular uses or applications for manufacturing or servicing
    • B64U2101/26—UAVs specially adapted for particular uses or applications for manufacturing or servicing for manufacturing, inspections or repairs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
    • B64U2101/00—UAVs specially adapted for particular uses or applications
    • B64U2101/30—UAVs specially adapted for particular uses or applications for imaging, photography or videography
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
    • B64U2201/00—UAVs characterised by their flight controls
    • B64U2201/10—UAVs characterised by their flight controls autonomous, i.e. by navigating independently from ground or air stations, e.g. by using inertial navigation systems [INS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64U—UNMANNED AERIAL VEHICLES [UAV]; EQUIPMENT THEREFOR
    • B64U2201/00—UAVs characterised by their flight controls
    • B64U2201/20—Remote controls
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D15/00—Apparatus or tools for roof working
    • E04D15/04—Apparatus or tools for roof working for roof coverings comprising slabs, sheets or flexible material

Definitions

  • the present invention describes an aerial drone for repairing holes or punctures in a membrane on a roof, a system for repairing holes or punctures in a membrane on a roof, and a method for repairing holes or punctures in a membrane on a roof.
  • thermoplastic single- and multi-ply membranes which are most often based on TPOs (thermoplastic olefins), PVC, or EPDM.
  • TPOs thermoplastic olefins
  • EPDM EPDM
  • An alternative to such prefabricated membranes are liquid applied membranes (LAMs) which are based on 1-component or 2-component reactive compositions.
  • LAMs liquid applied membranes
  • Liquid applied membranes e.g. on the basis of polyurethanes (PUs) or silicones, cure after their application in order to gain their final physical properties. Due to age, accidental damages, or harsh environmental conditions such as hailstorms, waterproofing membranes may become punctured and have holes, which should be repaired in order to ensure the waterproofing properties of the membrane.
  • an aerial drone for repairing holes or punctures in a membrane on a roof, characterized in that the aerial drone comprises at least one camera for recording a section of the membrane and a 3D printer adapted to print onto the section of the membrane, wherein the 3D printer is controllable wirelessly from a different altitude and/or the ground.
  • the present invention provides an unmanned aerial drone (such as an octocopter) that carries a tool that can be controlled remotely and operated to repair small holes or punctures in the membrane on a roof.
  • the tool that is carried is a 3D printer, for example a fused deposition modeling (FDM) 3D (three-dimensional) printer capable of printing directly onto the surface of the roof.
  • FDM fused deposition modeling
  • Aerial drones are well known in the art and the basic setup of the aerial drone does not need to be explained here.
  • the aerial drone, respectively the drone, of the invention comprises elements and functions of commercially available aerial drones. However, the aerial drone of the invention additionally comprises features and components named in claim 1 .
  • the invention allows repairs to be performed remotely from the safety of the ground, or automatically performed by an autonomous drone capable of detecting damage and depositing a patch to repair the membrane on the roof.
  • the 3D printer is attached to the bottom (side) of the aerial drone.
  • the 3D printer is attached to the bottom (side) of the aerial drone such that the 3D printer is centered between the legs of the drone in landing position.
  • the at least one camera for recording a section of the membrane is adapted to record after landing of the aerial drone on the membrane on the roof.
  • the at least one camera for recording a section of the membrane is adapted to record only after landing of the aerial drone on the membrane on the roof.
  • the aerial drone can control the printing itself or print under external control.
  • the at least one camera for recording a section of the membrane is adapted to be part of the aerial drone's flight system. This means the recordings of the camera are used for flying of the aerial drone and/or directing the aerial drone's movement.
  • the section of the membrane onto which the 3D printer is adapted to print is the section of the membrane with holes or punctures.
  • the at least one camera for recording a section of the membrane is adapted to record a section of the membrane on the roof between the legs of the drone in landing position.
  • the at least one camera for recording a section of the membrane is adapted to be focused on a level corresponding to a level on which the distal ends of the legs of the aerial drone are in landing position.
  • the at least one camera for recording a section of the membrane is adapted to record the membrane during flight of the aerial drone. This embodiment is useful to detect holes or punctures in a membrane on a roof using the aerial drone.
  • the at least one camera for recording a section of the membrane is one camera.
  • This embodiment saves weight, which allows a longer flight time for the aerial drone and/or saves weight for other features.
  • the 3D printer is controllable wirelessly from a different altitude and/or the ground.
  • the 3D printer is controlled wirelessly from a different altitude and/or the ground.
  • the aerial drone comprises at least one on-board communication unit, wherein the at least one on-board communication unit is adapted to wirelessly receive commands for the 3D printer from a ground based communication unit and optionally to transfer the commands to the 3D printer.
  • the on-board communication unit allows that the 3D printer can be controlled from a ground based communication unit.
  • the on-board communication unit preferably is an integral component of the 3D printer or more preferably is a separate component that transfers the received commands via a link, e.g. a cable.
  • the aerial drone comprises at least one on-board communication unit, wherein the at least one on-board communication unit is adapted to receive recordings from the at least one camera and to wirelessly send the recordings to a ground based communication unit.
  • the at least one on-board communication unit allows that recordings from the at least one camera can be sent to a ground based communication unit.
  • the section of the membrane can be observed before, during, and after printing.
  • the aerial drone comprises at least one on-board communication unit, wherein the at least one on-board communication unit is adapted to wirelessly receive commands for the 3D printer from a ground based communication unit and optionally to transfer the commands to the 3D printer and wherein the at least one on-board communication unit is adapted to receive recordings from the at least one camera and to wirelessly send the recordings to a ground based communication unit.
  • the at least one camera for recording a section of the membrane is one camera and the at least one on-board communication unit is one on-board communication unit. In specific embodiments, the at least one on-board communication unit is one on-board communication unit.
  • the at least one camera for recording a section of the membrane is adapted to provide recordings to the at least one on-board communication unit.
  • the 3D printer is a fused deposition modeling 3D printer.
  • the 3D printer is a fused deposition modeling 3D printer capable of printing using a filament or capable of printing using pellets. In specific embodiments, the 3D printer is a fused deposition modeling 3D printer capable of printing using a filament. In specific embodiments, the 3D printer is a fused deposition modeling 3D printer capable of printing using pellets. In specific embodiments, the fused deposition modeling 3D printer is a pellet extruder.
  • the 3D printer is a fused deposition modeling 3D printer, which is controllable wirelessly from a different altitude and/or the ground. In preferred embodiments, the 3D printer is a fused deposition modeling 3D printer, which is controlled wirelessly from a different altitude and/or the ground.
  • a fused deposition modeling 3D printer is light and suitable to directly print from its nozzle onto a surface such as the membrane. The nozzle can be moved swiftly in order to print on a larger portion of the section.
  • the 3D printer is capable of printing directly onto the surface of the roof. In preferred embodiments, the nozzle of the 3D printer is capable of printing directly onto the surface of the roof.
  • the aerial drone respectively the 3D printer comprises printing material.
  • filament is known in the art and describes printing material that is used by a fused deposition modeling 3D printer in order to print.
  • a pellet extruder can be used as fused deposition modeling 3D printer.
  • pellet extruders and pellets are well known in the art and pellets are printing material that can be used by the fused deposition modeling 3D printer in order to print.
  • the printing material is fed into the hot end respectively nozzle of the fused deposition modeling 3D printer and runs molten from the nozzle on the surface to be printed.
  • the aerial drone respectively the 3D printer comprises at least one filament (as printing material).
  • the filament is adapted to be fed into the hot end respectively nozzle of the fused deposition modeling 3D printer.
  • the filament is preferably stored on a spool.
  • the filament is a flexible filament.
  • the filament is a flexible filament, which is stored on a spool.
  • the filament is of a thickness of 1.25 mm to 3.5 mm.
  • Flexible filaments which can be stored on a spool, save space on the aerial drone.
  • the aerial drone respectively the 3D printer comprises pellets (as printing material).
  • the aerial drone respectively the 3D printer comprises printing material, wherein the printing material preferably contains polyvinyl chloride and/or polyurethane and/or thermoplastic olefin and/or ethylene propylene diene monomer rubber and/or bitumen.
  • the printing material preferably contains polyvinyl chloride and/or polyurethane and/or thermoplastic olefin and/or ethylene propylene diene monomer rubber and/or bitumen.
  • Polyvinyl chloride and/or polyurethane and/or thermoplastic olefin and/or ethylene propylene diene monomer rubber and/or bitumen is compatible with the material of liquid applied membranes and has waterproofing properties.
  • the aerial drone respectively the 3D printer comprises printing material, wherein the printing material preferably contains polyvinyl chloride and/or polyurethane and/or thermoplastic olefin and/or ethylene propylene diene monomer rubber and/or bitumen and/or PLA (Polylactide).
  • the printing material preferably contains polyvinyl chloride and/or polyurethane and/or thermoplastic olefin and/or ethylene propylene diene monomer rubber and/or bitumen and/or PLA (Polylactide).
  • the aerial drone respectively the 3D printer comprises printing material, wherein the printing material preferably contains polyvinyl chloride and/or polyurethane and/or thermoplastic olefin and/or ethylene propylene diene monomer rubber and/or bitumen.
  • the aerial drone respectively the 3D printer comprises printing material containing polyvinyl chloride and/or polyurethane.
  • the printing material containing polyvinyl chloride and/or polyurethane is heat stabilized up to temperatures of 300° C. or 280° C.
  • temperatures of 190° C. to 300° C., preferably 210° C. to 260° C. are required at the hot end of the 3D printer in order to print using (flexible) filaments from polyvinyl chloride. It has been found that heat stabilization allows printing using (flexible) filaments from polyvinyl chloride by prevention of thermal degradation.
  • the aerial drone comprises several printing materials, optionally containing different materials.
  • the verb “to contain” and its conjugations include the verb “to consist of” and its conjugations.
  • the verb “to comprise” and its conjugations include the verb “to consist of” and its conjugations.
  • the aerial drone has a weight of 1 kg to 25 kg, preferably 4 kg to 16 kg, more preferably 7 kg to 13 kg, most preferably 9 kg to 12 kg.
  • the inventors have prepared an aerial drone that can solve the technical problem, i.e. an aerial drone for repairing holes or punctures in a membrane on a roof. Surprisingly, the number of components and the sum of the weight of all components was successfully minimized to the given weight range. As a result, the aerial drone with all its features (and tools) has a weight, which can be driven by a battery for a sufficient operation/flight time.
  • the aerial drone comprises at least one battery unit with a sum of electric charge of 14000 mAh to 30000 mAh, preferably 19000 mAh to 27000 mAh, for providing power to at least one motor of the drone.
  • the sum of electric charge of 14000 mAh to 30000 mAh, preferably 19000 mAh to 27000 mAh describes how much electric charge is available from the battery respectively all batteries of the aerial drone for driving the motor respectively all motors of the aerial drone.
  • This electric charge preferably refers to the electric charge available to the at least one motor of the drone, and not to the 3D printer, camera etc.
  • the inventors have prepared an aerial drone that can solve the technical problem, i.e. an aerial drone for repairing holes or punctures in a membrane on a roof.
  • the inventors have found the optimal electric charge required to drive the aerial drone, which is a compromise between a too heavy but powerful battery and a light but insufficient battery. As a result, the aerial drone with all its features (and tools) can be driven by a battery with an optimal weight for a sufficient operation/flight time.
  • the aerial drone has a weight of 1 kg to 25 kg, preferably 4 kg to 16 kg, more preferably 7 kg to 13 kg, most preferably 9 kg to 12 kg, and the aerial drone comprises at least one battery unit with a sum of electric charge of 14000 mAh to 30000 mAh, preferably 19000 mAh to 27000 mAh, for providing power to at least one motor of the drone.
  • the sum of electric charge of 14000 mAh to 30000 mAh, preferably 19000 mAh to 27000 mAh describes how much electric charge is available from the battery respectively all batteries of the aerial drone for driving the motor respectively all motors of the aerial drone.
  • This electric charge preferably refers to the electric charge available to the at least one motor of the drone, and not to the 3D printer, camera etc.
  • the aerial drone with all its features (and tools) has a weight for which the electric charge of the battery is optimal for a sufficient operation/flight time.
  • the at least one on-board communication unit is a microcomputer, preferably a single-board computer or a Raspberry Pi, with an operating system, preferably Octoprint, installed. If the at least one on-board communication unit and the 3D printer are not one integral component, the at least one on-board communication unit is connected to the 3D printer, preferably via USB cable.
  • a microcomputer such as a single-board computer or a Raspberry Pi, is very light, requires little space and can be easily attached to the aerial drone. Further, these require only a small and light battery, which further reduces the weight of the aerial drone.
  • the at least one on-board communication unit is a single-board computer.
  • the at least one on-board communication unit is one on-board communication unit and the sum of the weight of the on-board communication unit and of all cameras for recording the section of the membrane is 1 g to 300 g, preferably 1 g to 150 g, most preferably 1 g to 80 g.
  • This setup further reduces the weight of the aerial drone. Few connecting parts or other heavy and expensive imaging components are required.
  • the at least one on-board communication unit is one on-board communication unit and the at least one camera for recording the section of the membrane is one camera, wherein the on-board communication unit and the camera in sum have a weight of 1 g to 300 g, preferably 1 g to 150 g, most preferably 1 g to 80 g.
  • This setup further reduces the weight of the aerial drone. Few connecting parts or other heavy or expensive imaging components are required.
  • the at least one on-board communication unit is one single-board computer and the sum of the weight of the single-board computer and of all cameras for recording the section of the membrane is 1 g to 300 g, preferably 1 g to 150 g, most preferably 1 g to 80 g.
  • This setup further reduces the weight of the aerial drone. Few connecting parts or other heavy or expensive imaging components are required.
  • the aerial drone comprises one camera for recording a section of the membrane, but no further cameras.
  • one camera for recording a section of the membrane has a weight of 1 g to 20 g, preferably 1 g to 10 g.
  • all cameras of the aerial drone have a total weight of 1 g to 50 g, preferably 1 g to 30 g.
  • the aerial drone is an octocopter.
  • the aerial drone has landing legs with a length of 15 cm to 90 cm, preferably 35 cm to 80 cm.
  • a further object of the invention is to provide a system for repairing holes or punctures in a membrane on a roof, which reduces the need for workers to be on roofs and which automates the roof repair and maintenance process.
  • the system comprises an aerial drone according to claims 1 to 7 , preferably according to claims 2 to 7 , and a ground based communication unit adapted to wirelessly send commands for the 3D printer to the on-board communication unit of the aerial drone and/or adapted to wirelessly receive recordings from the at least one camera via the on-board communication unit.
  • the on-board communication unit and the ground based communication unit are connected by a wireless network.
  • the ground based communication unit is preferably a personal computer, laptop, or smart phone.
  • the combination of connected on-board communication unit and ground based communication unit allows that recordings from the at least one camera of the aerial drone can be sent to a ground based communication unit.
  • the section of the membrane can be observed before, during, and after printing.
  • the combination of connected on-board communication unit and ground based communication unit allows that the 3D printer can be controlled precisely from the ground based communication unit.
  • the on-board communication unit is accessible (remotely) via the wireless network via an operating system installed on the on-board communication unit and optionally on the ground based communication unit.
  • the wireless network is a wireless hotspot generated by a smart phone. This allows a quick setup of the system by the human at the site where the membrane and roof is installed.
  • the operating system of the on the on-board communication unit is Octoprint.
  • the on-board communication unit respectively the single-board computer or Raspberry Pi, is accessible remotely via browser using Octoprint.
  • Octoprint also supports single-board computers with camera.
  • the wireless network is a wireless hotspot generated by a smart phone and the operating system of the on the on-board communication unit is Octoprint.
  • a further object of the invention is to provide a method for repairing holes or punctures in a membrane on a roof, which reduces the need for workers to be on roofs and which automates the roof repair and maintenance process.
  • the method comprises the steps of detecting at least one hole or puncture in a section of the membrane on the roof, of recording at least the section of the membrane with at least one camera of an aerial drone according to claims 1 to 7 , of landing an aerial drone according to claims 1 to 7 on the membrane on the roof such that the 3D printer of the aerial drone can print onto the section of the membrane, in particular onto at least one hole or puncture, and of printing onto the section of the membrane, in particular onto the at least one hole or puncture, using the 3D printer and preferably printing material of the aerial drone.
  • step of printing will be the last of these steps in most embodiments.
  • step of detecting and the step of recording may be simultaneous or the recording may take place prior to detecting.
  • the step of detecting at least one hole or puncture in a section of the membrane on the roof is conducted by a human on the roof, by a human using an aerial drone or automatically by an aerial drone.
  • the step of recording at least the section of the membrane with at least one camera of an aerial drone can be done in several manners: In specific embodiments, the at least one camera records after landing of the aerial drone on the membrane on a roof. In specific embodiments, the at least one camera records only after landing of the aerial drone on the membrane on a roof. Preferably, the section has been found to have at least one hole or puncture before landing of the aerial drone. For an effective use of the 3D printer, it is necessary that the at least one camera records the section of the membrane with holes or punctures. Based on the recordings, the aerial drone controls the printing itself or the printing is controlled externally.
  • the recording of at least the section of the membrane with at least one camera is part of the flying operation of the aerial drone. This means the recordings of the camera are used for flying of the aerial drone and/or directing the aerial drone's movement.
  • the at least one camera for recording a section of the membrane records during flight of the aerial drone. This embodiment is useful to detect holes or punctures in a membrane on a roof.
  • the at least one camera for recording a section of the membrane records a section of the membrane on the roof between the legs of the drone in landing position.
  • the section of the membrane onto which the 3D printer prints is part of the section of the membrane that is recorded by the at least one camera.
  • the at least one camera for recording a section of the membrane provides recordings to the at least one on-board communication unit.
  • the at least one camera for recording a section of the membrane provides recordings of at least the section of the membrane to the at least one on-board communication unit.
  • the step of landing an aerial drone according to claims 1 to 7 on the membrane on the roof is conducted such that the 3D printer of the aerial drone can print onto the section of the membrane, in particular onto at least one hole or puncture.
  • the nozzle of the 3D printer which preferably is movable, can reach the section of the membrane to be printed on, in particular the at least one hole or puncture.
  • the method comprises a step at a ground based communication unit of wirelessly receiving recordings of at least the section of the membrane from at least one camera and sending commands for the 3D printer to the 3D printer via at least one on-board communication unit of the aerial drone.
  • the ground based communication unit is preferably a personal computer, laptop, or smart phone. This step allows that the method is precisely controlled by a human at the ground based communication unit, who receives live images from the printing site. The human has no risk of falling from the roof.
  • the method comprises a step at a ground based communication unit of wirelessly receiving recordings of at least the section of the membrane from at least one camera via at least one on-board communication unit of the aerial drone.
  • the ground based communication unit is preferably a personal computer, laptop, or smart phone. This step allows that the method can be supervised by a human at the ground based communication unit, who receives live images from the printing site. The human has no risk of falling from the roof.
  • the method comprises a step at a ground based communication unit of wirelessly sending commands for the 3D printer to the 3D printer via at least one on-board communication unit of the aerial drone.
  • the ground based communication unit is preferably a personal computer, laptop, or smart phone.
  • the method comprises a step of setting up a wireless network, preferably a wireless hotspot using a smart phone, between the on-board communication unit and the ground based communication unit.
  • a wireless network enables communication between the at least one on-board communication unit of the aerial drone and the ground based communication unit.
  • a wireless hotspot can be setup quickly using a smart phone at the site of the building with the roof in order to enable wireless communication.
  • the temperature of a hot end of the 3D printer is set to 190° C. to 300° C., preferably 210° C. to 260° C., during printing. It has been found that this temperature is required for extrusion of specific printing materials such as (flexible) filament from polyvinyl chloride.
  • the method according to the invention is conducted by the aerial drone automatically or is controlled and/or supervised by a human operator at the ground based communication unit.
  • the membrane on the roof contains polyvinyl chloride and/or polyurethane and/or thermoplastic olefin and/or the membrane on the roof is a liquid applied membrane.
  • the membrane on the roof contains polyvinyl chloride and/or polyurethane.
  • the membrane on the roof is a liquid applied membrane.
  • the membrane on the roof is a thermoplastic olefin.
  • the membrane on the roof contains thermoplastic olefin.
  • FIG. 1 shows an aerial drone and a system according to the invention.
  • a CoLiDo D1315 FDM 3D printer was employed as 3D printer 5 for this example.
  • the stock baseplate for the 3D printer 5 was replaced with a custom base to allow for direct to surface 3D printing.
  • the custom base is a circular object cut from 1 ⁇ 4′′ Plexiglas with the same diameter as the original base. A large hole was cut in the center of the base to allow for direct to surface printing. Additional holes were drilled in the custom base to allow for the original screws to be used to attach the base to the printer 5 .
  • the 3D printing software prevents the print head 9 , 12 of CoLiDo D1315 FDM 3D from moving to a Z-position that is lower than the surface of the print area of the stock baseplate. These restrictions are designed to prevent damage to the print head 9 , 12 , but make direct to surface printing impossible without further modification to the software or CoLiDo D1315 FDM 3D printer 5 .
  • PLA Polylactide
  • the filament was arranged to be fed from a spool into the CoLiDo D1315 FDM 3D printer 5 .
  • a Raspberry Pi 3 Model B as on-board communication unit 8 and a Raspberry Pi NoIR Camera V2 as camera 3 for recording a section of the membrane were connected.
  • Mudder black aluminum heat sinks for the Raspberry Pi Model B were used.
  • a TONV Power Bank battery was connected via a male USB to male MicroUSB cable to the Raspberry to power the Raspberry 8.
  • a TalentCell 12 V Power Bank battery was connected via a DC connector to power the printer 5 .
  • the Raspberry Pi 8 and the printer 5 were connected via a USB 2.0 male A to male B cable.
  • a microcomputer 8 known as a Raspberry Pi was used to enable the 3D printer 5 to receive print commands wirelessly.
  • the Pi 8 basically acts as a very small computer that can be attached to the printer 5 and can send print commands via USB cable.
  • the Pi 8 can be accessed remotely via browser using an operating system known as OctoPrint. Therefore it is possible to send print commands from a browser window that is opened on a PC 7 or smart phone 7 to the Pi 8 over a Wi-Fi network. Once the commands are received by the Pi 8 they can be executed by the printer 5 to print an object.
  • OctoPrint was installed on the Pi 8 by downloading the program and writing the image to an SD card. Inserting the SD card into the Pi 8 allows OctoPrint to boot up upon powering up the Pi 8.
  • the Pi 8 To receive print commands the Pi 8 must be connected to the same wireless network as another device such as a smart phone 7 , or PC 7 , or laptop 7 . This was achieved by editing a wireless access program file in OctoPrint to allow the Pi 8 to connect to the wireless hotspot generated by an iPhone 7. Once connected, other devices connected to the same wireless hotspot (such as a PC 7 or the iPhone 7 itself) can communicate with the Pi 8.
  • a browser window is opened and the IP address for the Pi 8 is entered into the browser.
  • the IP address for the Pi 8 can be determined by connecting the Pi 8 to a monitor using an HDMI cable, powering up the Pi 8 and logging in using a keyboard connected to the Pi 8. The IP address will be displayed on the monitor. Once the correct IP address is entered, the interface for OctoPrint will load in the browser window. From here g-code files can be uploaded and print commands can be given wirelessly. OctoPrint also supports the Raspberry Pi camera 3 and can provide a live feed of the print job. To demonstrate the wireless printing capabilities a small Sika logo was successfully printed.
  • the printer 5 could successfully receive print commands wirelessly the range of the wireless connection was determined.
  • the printer 5 was placed outside and the Pi 8 and a laptop 7 were connected to the wireless hotspot generated by an iPhone 7. The iPhone 7 and the laptop were then moved away from the printer 5 .
  • the Pi 8 was still connected to the wireless network when it was approximately 200 ft. away from the iPhone 7.
  • a test print was performed at a range of approximately 100 feet and was successful.
  • Batteries were used to power the 3D printer 5 so that it could operate without being connected to any stationary power sources. This was achieved by acquiring a battery capable of powering the printer 5 and one to power the Pi 8 (and the Pi camera 3 ). The batteries were attached to the printer 5 with Velcro and were used to power the respective devices. A test print was successfully performed using the batteries as a power source. Used in conjunction with the wireless printing capability, the battery power provides mobility to the 3D printer 5 that is required for its use as a component of a 3D printer drone 1 .
  • the 3D printer 5 can be battery powered.
  • DJI Spreading Wings 51000+ drone with DJI A2 flight control system Futaba T14SG radio controller Tattu 22000 mAh 6C LiPo battery, MaxAmps 24 V power supply, Hyperion EOS 0840i 1000 W charger, and CineMilled DJI S1000/Ronin-M Extended Carbon Fiber Landing Gear was employed in this example.
  • the above modified CoLiDo D1315 FDM 3D printer 5 was attached to the bottom of the aerial drone.
  • the printer was attached to the gimbal mount of the drone using heavy duty cable ties.
  • Two cable ties were wrapped around each of the three legs of the printer and the gimbal mounting base. The ties were tightened as much as possible and the printer was found to be tightly attached.
  • a mechanism such as screwing the top plate of the 3D printer to the gimbal mounting base may also be employed. All other components were attached as well using standard means such as Velcro, glue, etc. According to the manual for the DJI Spreading Wings 51000+ drone, the maximum takeoff weight for the drone is 11 kg.
  • the takeoff weight of the drone 1 fully loaded with the modified 3D printer, battery, and all other components is just about 11 kg.
  • a 22000 mAh battery was attached to the drone such that it powers the motors of the drone 1 .
  • a test flight was successfully performed with a takeoff weight of the drone of about 9 kg. After about 8 minutes of flight time, less than half of the battery power was consumed. Therefore, it has been shown that the drone is powerful enough to lift the modified 3D printer 5 and all required components with an optimized weight for a sufficient amount of time in order to repair the membrane on a roof.
  • the inventors have developed means, i.e. a drone 1 , a system 8 , and a method 10 , for repairing holes or punctures in a membrane on a roof 2 , which reduce the need for workers to be on roofs and which automate the roof repair and maintenance process.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Working Measures On Existing Buildindgs (AREA)
  • Coating Apparatus (AREA)
US16/140,048 2018-09-24 2018-09-24 Roof repair drone Abandoned US20200094958A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US16/140,048 US20200094958A1 (en) 2018-09-24 2018-09-24 Roof repair drone
JP2021514512A JP7545387B2 (ja) 2018-09-24 2019-09-24 屋根修理用ドローン
US17/265,676 US20210300556A1 (en) 2018-09-24 2019-09-24 Roof repair drone
PCT/EP2019/075757 WO2020064766A1 (en) 2018-09-24 2019-09-24 Roof repair drone
EP19774098.8A EP3856632A1 (en) 2018-09-24 2019-09-24 Roof repair drone
CN201980059891.9A CN112739620A (zh) 2018-09-24 2019-09-24 屋顶修复无人机

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US16/140,048 US20200094958A1 (en) 2018-09-24 2018-09-24 Roof repair drone

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US17/265,676 Continuation US20210300556A1 (en) 2018-09-24 2019-09-24 Roof repair drone

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US11529777B2 (en) * 2020-02-05 2022-12-20 The Boeing Company Hot bond repair of structures using unmanned aerial vehicles

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US20210300556A1 (en) 2021-09-30
EP3856632A1 (en) 2021-08-04
JP2022501532A (ja) 2022-01-06
WO2020064766A1 (en) 2020-04-02
CN112739620A (zh) 2021-04-30

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