WO2020136563A2 - Assembleur structurel - Google Patents

Assembleur structurel Download PDF

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Publication number
WO2020136563A2
WO2020136563A2 PCT/IB2019/061303 IB2019061303W WO2020136563A2 WO 2020136563 A2 WO2020136563 A2 WO 2020136563A2 IB 2019061303 W IB2019061303 W IB 2019061303W WO 2020136563 A2 WO2020136563 A2 WO 2020136563A2
Authority
WO
WIPO (PCT)
Prior art keywords
robot
brick
structural unit
connecting material
structural units
Prior art date
Application number
PCT/IB2019/061303
Other languages
English (en)
Other versions
WO2020136563A3 (fr
Inventor
Ivo TEDBURY
Felix VAUGHAN
Original Assignee
Semblr Technologies Limited
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 Semblr Technologies Limited filed Critical Semblr Technologies Limited
Publication of WO2020136563A2 publication Critical patent/WO2020136563A2/fr
Publication of WO2020136563A3 publication Critical patent/WO2020136563A3/fr

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Classifications

    • 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
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/14—Conveying or assembling building elements
    • E04G21/16—Tools or apparatus
    • E04G21/22—Tools or apparatus for setting building elements with mortar, e.g. bricklaying machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J15/00—Gripping heads and other end effectors
    • B25J15/02—Gripping heads and other end effectors servo-actuated
    • B25J15/0253—Gripping heads and other end effectors servo-actuated comprising parallel grippers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J5/00—Manipulators mounted on wheels or on carriages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J5/00—Manipulators mounted on wheels or on carriages
    • B25J5/005—Manipulators mounted on wheels or on carriages mounted on endless tracks or belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D57/00—Vehicles characterised by having other propulsion or other ground- engaging means than wheels or endless track, alone or in addition to wheels or endless track
    • B62D57/02—Vehicles characterised by having other propulsion or other ground- engaging means than wheels or endless track, alone or in addition to wheels or endless track with ground-engaging propulsion means, e.g. walking members
    • B62D57/032—Vehicles characterised by having other propulsion or other ground- engaging means than wheels or endless track, alone or in addition to wheels or endless track with ground-engaging propulsion means, e.g. walking members with alternately or sequentially lifted supporting base and legs; with alternately or sequentially lifted feet or skid
    • 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
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/14—Conveying or assembling building elements
    • E04G21/16—Tools or apparatus
    • E04G21/20—Tools or apparatus for applying mortar
    • E04G21/202—Hoses specially adapted therefor
    • 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
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/14—Conveying or assembling building elements
    • E04G21/16—Tools or apparatus
    • E04G21/18—Adjusting tools; Templates
    • E04G21/1808—Holders for bricklayers' lines, bricklayers' bars; Sloping braces
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/45—Nc applications
    • G05B2219/45086—Brick laying, masonry robot

Definitions

  • the present invention relates to systems and methods for assembly of a structure. More specifically, the invention relates to systems and methods for automatic assembly of a structure comprising a plurality of structural units. In particular, the invention relates to systems and methods for the automatic assembly of a structure comprising a plurality of bricks.
  • Structural units such as bricks or blocks, may be connected together in order to assemble a structure comprising hundreds, thousands, or even millions of structural units.
  • a backyard pizza oven may comprise around 250 bricks; a house may comprise around 10,000 bricks; and a very large warehouse may comprise around 27 million bricks.
  • the process of assembling a structure using a plurality of structural units is, and has been for millennia, a laborious, time-consuming, and often dangerous manual activity for human workers.
  • machines are sometimes used. For instance, to lift structural units from a supply point and place them in position on a structure.
  • conventional machines such as industrial arms, SCARA and Cartesian robots have a finite working zone, determined from a‘global’ origin of the robot (e.g. the calibration point). This fundamental infrastructural constraint limits the form and size of the buildable product.
  • These machines can be mounted on a carriage which traverses along a gantry system, but this still results in a single build area which is equal to or larger than in size to the target structure.
  • Another adaptation is to mount the machine on a mobile platform equipped with caterpillar tracks or wheels, but this limits the working zone to traversable floor surface, distinct from the structure being assembled.
  • the inventors have developed systems and methods which overcome the problems with known assembly systems.
  • the invention relates to systems and methods for assembling a structure out of a plurality of structural units, wherein the system comprises at least one robot.
  • the invention relates to a robot for assembling a structure out of a plurality of structural units.
  • the invention relates to hardware or additional hardware for use in an assembly system, wherein the assembly system comprises at least one robot.
  • the invention relates to a system and method for controlling a robot as the robot assembles a structure out of a plurality of structural units.
  • the invention relates to a system and method for orchestrating a plurality of robots to assemble a structure out of a plurality of structural units.
  • the invention relates to systems and methods for disassembling a structure comprising a plurality of structural units, wherein the system comprises at least one robot.
  • the invention relates to a robot for disassembling a structure comprising a plurality of structural units.
  • the robot of any aspect may be configured to manoeuvre around the structure by climbing or traversing the structure.
  • the robot of any aspect may comprise a robot body; a first foot coupled to the robot body and a second foot coupled to the robot body, wherein the first and second feet are configured to move relative to the robot body and each other; and an effector coupled to the robot body.
  • the first and second feet may be on opposite sides of the robot body.
  • the robot of any aspect may include a connecting material storage and delivery system, a structural unit positioning system, a structural unit position correcting system, a robot balance system, a collision avoidance system, and/or a robot positioning system.
  • the robot of any aspect may be configured to carry structural units, such as masonry bricks.
  • the robot of any aspect may be configured to obey valve constraints which determine in which directions the robot may travel on a path.
  • the robot of any aspect may be configured to perform checks at checkpoint positions on the structure.
  • the additional hardware may be a bypass system for placement in an opening in the structure, wherein bypass structure provides a continuous path from one side of the opening to the other.
  • the additional hardware may be a path for placement between points in an assembly system.
  • the additional hardware may be a staircase system, where the staircase system provides a plurality of steps between a plurality of access levels.
  • the access levels may provide access to a structure, or access to a pallet of structural units.
  • the plurality of access levels may be at heights corresponding to, say, every second, third, or fourth step. In a preferred embodiment, the plurality of access levels are at heights corresponding to every third step.
  • the invention may comprise one, some, any or all of the features described herein, and if more than one such feature, those features in any appropriate combination. Any, some and/or all features in one aspect can be applied to any, some and/or all features in any other aspect, in any appropriate combination. It should also be appreciated that particular combinations of the various features described and defined in any aspects of the invention can be implemented and/or supplied and/or used independently.
  • Figure 1 shows a close-up diagram of an exemplary robot.
  • Figure 2 shows twelve exemplary diagrams illustrating the intermediate configurations of the robot joints during a step- up action onto a brick.
  • Figure 3 shows twelve diagrams illustrating exemplary intermediate configurations of the robot joints during a step-up action onto a brick.
  • Figure 4 shows a perspective view of an example mortar storage and delivery system.
  • Figure 5 shows a perspective view of an example nozzle fitting attached to the end of the mortar container cylinder.
  • Figure 6 shows a perspective view of an exemplary mortar storage unit, robot unit and custom dispenser apparatus which interfaces between the two.
  • Figure 7 shows perspective views of examples of a robot refilling itself with mortar from a storage unit.
  • Figure 8 shows a perspective view of the exposed workings of an exemplary robot gripper, shown clasping a typical brick.
  • Figure 9 shows a perspective view of the underside of the exemplary robot gripper, shown without a brick in place.
  • Figure 10 is a diagram of the exemplary robot configuration just after it has spread the mortar for a brick to be laid.
  • Figure 11 is a diagram of the exemplary robot configuration just before placing a brick on a brick wall.
  • Figure 12 is a diagram of the exemplary robot configuration as it places the brick in the mortar.
  • Figure 13 shows twelve diagrams illustrating the intermediate configurations of the exemplary robot during the brick placement action.
  • Figure 14 shows a perspective view of an exemplary pallet of bricks which have been specially prepared to allow robot access.
  • Figure 15 shows the above exemplary pallet after it has been packed.
  • Figure 16 shows an exemplary large container for the transportation and storage of a large volume of bricks.
  • Figure 17 shows a perspective view of an exemplary storage area and integrated staircase for bricks on site.
  • Figure 18 illustrates at a high level an exemplary software process taking a BIM model design of a structure all the way through to the actions of the robot.
  • Figure 19 shows an exemplary flow diagram for the software the computes the robot’s location based on a range of sensory information.
  • Figure 20 is a diagram illustrating an exemplary high level control flow for the robot when placing a brick.
  • Figure 21 is a diagram showing example situations where valves and checkpoints are used to control the flow of robots.
  • Figure 22 shows a perspective view of an exemplary robot vertical transportation device or lift.
  • Figure 23 shows a side elevation view of an example robot vertical transportation device.
  • Figure 24 shows an exemplary sequence of perspective views of an example robot vertical transportation device.
  • Figure 25 shows an exemplary staircase that enables the robot to access different heights of the brick structure.
  • Figure 26 shows a side-on view of the exemplary staircase design.
  • Figure 27 illustrates the design of the staircase shown in Figure 25 positioned in front of a brick wall.
  • Figure 28 shows a perspective view of an exemplary bypass structure on its own.
  • Figure 29 shows a side on view of an exemplary bypass structure.
  • Figure 30 shows an exemplary perspective view of a design for a bypass structure, here shown enabling the robot to bypass a window gap in the brick wall structure shown behind.
  • Figure 31 contains a diagram showing a plan view of an exemplary construction site during the build process.
  • Figure 32 shows an example of a unit designed to allow the robots to charge their batteries autonomously.
  • Figure 33 contains three exemplary diagrams of the possible network connections between the robots and a central controller.
  • Figure 34 shows an exemplary ramp structure which allows wheeled access levels of a pallet.
  • Figure 35 shows a ramp structure that enables wheeled access to intermediate levels of a straight brick or block structure.
  • Figure 36 shows an example active ramp from a first perspective.
  • Figure 37 show the example active ramp of Figure 36 from a second perspective.
  • Figure 38 illustrates an example use case of two active ramps.
  • Figure 39 shows an perspective view of a passive ramp on a brick structure.
  • Figure 40 shows a perspective view of a passive ramp raised above a brick structure.
  • Figure 41 illustrates an example use case of two passive ramps.
  • Figure 42 illustrates a number of bricks each comprising fiducial markers.
  • Figure 43 shows a perspective view of a marker and localisation system.
  • Figure 44 show a perspective view from below of a pointing attachment.
  • Figure 45 shows a perspective view of a pointing attachment in use by a robot on a brick structure.
  • Figure 46 is a first perspective view of an example robot placing a brick coated with mortar into position on a wall including on structure ramps.
  • Figure 47 is a second perspective view of the example robot placing a brick coated with mortar into position on a wall including on structure ramps of Figure 46.
  • Figure 48 is a perspective view of the example robot of Figure 46 and 47 as it places a brick into position in the wall.
  • Figure 49 shows an example of the steps by which a robot places a brick in brick structure using the passive ramps.
  • Figure 50 shows an example of the steps by which a robot may place a brick in brick structure without ramps.
  • Figure 51 shows an example system to localise a robot.
  • Figure 52 shows a flowchart of a build system with a material factory.
  • Figure 53 shows a flowchart of a brick placement method.
  • Figure 54 shows a perspective view of the robot in conjunction with a building material platform.
  • Figure 55 shows an illustration of an overall automated assembly system.
  • Figure 56 shows an illustration of an example robot.
  • Figure 57 shows a further illustration of an example robot.
  • Figure 58 contains a diagram showing a plan view of a further exemplary construction site during the build process.
  • Figure 59 shows a connecting material ladle system.
  • Figure 60 shows a robot refilling its connecting material via the connecting material ladle.
  • Figure 61 shows the connecting material ladle and rack therefor.
  • the automated assembly system comprises at least one robot configured to assemble a structure larger than itself.
  • the structure comprises a plurality of structural units, such as bricks or blocks, which are connected together.
  • the structural units may be connected with connecting materials, such as glue or mortar.
  • the structural units are bricks, and the connecting material is mortar.
  • the robot is configured to manoeuvre around a structure by climbing and/or traversing the structure itself, as well as assemble it.
  • the robot is configured such that it may carry at least one type of building material when manoeuvring around a structure.
  • the robot is configured to manoeuvre to a position on the structure whilst carrying building material, add at least part of the building material to the structure, and then manoeuvre away from that position on the structure.
  • the robot may be configured to carry both a structural unit and a connecting material.
  • the robot may be configured to add a structural unit and the connecting material required to connect that structural unit to the structure before manoeuvring away from a position on the structure.
  • the robot is controlled by an individual robot control program.
  • the robot comprises at least one on-board sensor in communication with the robot control program.
  • the robot control program may be configured to use the metrology of the structural units as discrete objects for orientation, location, and/or locomotion.
  • the robot may be configured to define its origin locally on the structure. At least one on board sensor may sense the robots real world environment. The robot may then simultaneously construct a map of its environment and keep track of its location within it. The robot is able to self-correct its local positioning by comparing the real world environment it senses with other sources of information, for example a model of the structure, imaging of the structure, or other sources.
  • the robot may also include at least one on-board sensor to sense the robot’s position in global space. Using the knowledge of where it is in global space, the robot may self-correct its local positioning.
  • the robots may be connected to an energy source.
  • the robots may comprise an energy source.
  • a robot may include a battery. The battery may be charged at a robot charging station.
  • the automated assembly system may include additional hardware on which robots may manoeuvre.
  • the automated assembly system may include additional hardware which robots use to climb up and/or down the structure, additional hardware which robots use to manoeuvre from one part of the structure to another, and/or additional hardware which robot use to traverse and/or climb up/or down areas off the structure.
  • the automated assembly system may include also include additional hardware configured to allow robots to bypass openings in the structure, such as gaps for windows and doors.
  • the robots may be configured to use many possible types of building material including, structural units, materials for connecting the structural units, and/or any other material used when assembling a structure. For example, bricks, mortar, and/or wall ties.
  • the robots may be configured to receive building material at a supply point.
  • a material supply point may supply a single type of building material, or multiple types of building material.
  • a structural unit supply point supplies a robot with structural units, such as bricks.
  • a connecting material supply point supplies a robot with materials for connecting the structural units, such as mortar.
  • a wall tie supply point supplies a robot with wall ties.
  • a combined supply point supplies a robot with a combination of building materials.
  • the robots may be configured to walk to the supply point to receive building materials.
  • the robot may be configured to receive building material at a supply point, manoeuvre to a location on the structure whilst carrying the building material, add at least part of the building material to the structure, and then manoeuvre away from that location on the structure.
  • the robot may then manoeuvre to a supply point to get more building material and repeat.
  • the robot may be configured to always walk/climb to the same supply point, or it may be configured to visit different supply points.
  • a robot may be configured to visit a first supply point to receive a first type of building material, and a second supply point to receive a second type of building material, wherein the first type of building material is different to the second type of building material.
  • supply points may be located and/or sized relative to how often a robot will need to resupply a given building material type.
  • the supply point may be optimised for supplying the given building material type. Consequently, the speed at which a structure is assembled is increased.
  • a robot may be configured to visit a first supply point before visiting a first location on a structure, and a second supply point after visiting the first location on the structure, wherein the first and second supply points are different. In this way, the flow of robots in the automated assembly system may be improved.
  • the robots of the present invention may be configured to use standard brick masonry as the structural units for assembling structures.
  • brick is still widely used today as a cladding and structural material
  • integration into industry - the technology works with the well-established materials, designs and processes of used in conventional bricklaying, meaning that the invention works within existing building regulations.
  • a robot is configured to manoeuvre, pickup, carry, and place bricks, carry and dispense mortar, apply a wall tie, and clean the excess mortar to leave a neat pointing style.
  • the robots of the present invention may be distributed, working in teams and making use of designed collective behaviour principles to coordinate their movements. Adding more robots, more material supply points, and more efficient robot flow s/coordination increases the speed of assembly. More and more robots can be added to the team until a saturation point is reached where there is no more space in the automated assembly system.
  • the automated assembly system of the present invention removes the height constraint of ground-based robots, allows for greater local accuracy, and more economical power consumption than known assembly systems.
  • the advantage over traditional off-structure robots is that the robots are far smaller and cheaper than would be required to assemble a structure of the same size.
  • the automated assembly system of the present invention may increase the speed at which a structure may be assembled, the complexity of the structures which may be assembled, and the accuracy with which structures may be assembled, as well as reduction or removal of labour costs.
  • the robot is configured to perform set of actions for the purposes of automatically assembling a structure.
  • the robot may be configured to pick up bricks and mortar from a material supply point, manoeuvre around the structure to a position on the structure, apply the mortar, place the brick, and then climb back to a material supply point or a charging point.
  • the robot’ s actions are implemented by its individual robot control program.
  • the robots actions are determined by analysing a model of the desired construction, such as a 3 dimensional (3D) model of the structure.
  • the robot actions are determined by analysing a Building Information Model of the structure.
  • the robot may analyse the model of the desired construction.
  • the robot may determine a map of its local environment and compare the map with a model of the desired construction.
  • the robot may use this comparison to determine its location and/or determine that alterations should be made to the structure. For example, the robot may determine that a brick should be moved, or that the amount of mortar should be changed. The robot may self-organize, and allocate the required steps with other robots. Alternatively, or in combination, the robots may communicate with a central computer which orchestrates the robots.
  • the robot is configured to: Pick up a brick; pick up a wall tie; fill with mortar; take a step along (traverse); take a step up (climb up); take a step down (climb down); make a turn through any angle; put a wall tie into position; apply mortar to the existing structure; place a brick; fine tune the position of the brick after placement; point the mortar and brush the mortar.
  • the robot comprises a track or other travelling means, and is configured to perform one, some or all of the following activities: Pick up a brick; pick up a wall tie; fill with mortar; drive along (traverse); drive up a ramp (climb up); drive down around a ramp (climb down); pick up a ramp; place a ramp; make a turn through any angle; put a wall tie into position; apply mortar to the existing structure; negotiate tight comers (e.g.
  • the robot comprises a robot body.
  • the robot body is where the majority of the motors, control boards and batteries may be situated. Motors may use belt drives or other mechanical linkage to transmit movement to the robot’s extremities.
  • the robot comprises two legs which are used for manoeuvring the robot.
  • the legs are each configured to move in a movement plane, horizontally and vertically relative to the robot body, in a linear fashion.
  • the legs slide along bearings which interface with the main chassis.
  • the legs are mounted on opposite sides of the chassis to allow the legs to pass each other when taking a step.
  • the legs are spaced wide enough apart to allow a structural unit to pass between them as the legs pass each other. Alternatively, they may be mounted closer together, but include a wider opening between them at some point over their length to allow a structural unity to pass between them.
  • the robot comprises a foot at the end of each leg.
  • the feet are mounted so that the underside or‘sole’ is horizontal. At least part of each foot extends from the leg to which it is coupled towards the opposite side of the robot body. In other words, the sole of each foot extends in a horizontal direction from the leg to which it is coupled towards the movement plane of the opposite leg.
  • the feet are able to rotate around a vertical axis. In some embodiments, the feet are configured to pivot in the other two axes, to mitigate for uneven ground or non horizontal structure surface.
  • the feet can have varying undersides or‘soles’ depending on what structural unit the robot is assembling a structure with.
  • the feet or feet soles are interchangeable with simple fixings or snap fit etc.
  • Figure 1 shows a close-up diagram of an exemplary robot 1000. It comprises two legs 1010 1011 that attach to the main chassis 1020 of the robot 1000 and move horizontally and vertically relative to it in a linear fashion. That is, they slide along bearings which interface with the main chassis 1020. They are mounted on opposite sides of the chassis to allow them to pass each other when taking a step. They are spaced wide enough apart to just allow a brick to pass through.
  • the feet 1030 1031 At the bottom of the legs are the feet 1030 1031.
  • the legs attach to the feet through a joint that is able to rotate about the vertical axis. This is illustrated by the cylindrical bearing between the leg and the base of the foot. This enables the robot to rotate the main chassis when standing on one leg.
  • the feet are mounted so that the‘sole’ is horizontal. Future additions could allow the feet to additionally pivot in the other two axes, so they could mitigate for uneven ground or non-horizontal structure surface.
  • the feet can have varying undersides or‘soles’ depending on what brick the robot is constructing with, for example: flat for flat bricks, a round protrusion to insert into bricks with round holes, a square protrusion to insert into bricks with square holes, a sculpted protrusion to fit into a frogged brick. These could be easily interchangeable with simple fixings or snap fit etc.
  • the end- effector or gripper 1040 Between the two legs and attached on the underside of the main chassis is the end- effector or gripper 1040. This moves horizontally along the main chassis independently of the two legs. It has a clasping mechanism (a set of jaws 1050) which can open or close to grip and hold a brick.
  • the left-hand jaw 1050 is seen as the rectangle protruding down from the bulk of the gripper. The jaws grip the long outer edges of the brick to allow smaller bricks to also be held when required. If perforated or frogged bricks are being used, the gripper may also hold the brick from the inside.
  • the two cylindrical puck shaped objects 1060 1061, one on the top of the main chassis and the other rotated 90 degrees at the head of the main chassis are the LIDAR scanners. These scan 360 degrees in a circular motion generating point-cloud data of the brick structure and surrounding environment. This data may be used as a record of the as-built structure as well as for localisation using Simultaneous Localisation and Mapping (SLAM).
  • SLAM Simultaneous Localisation and Mapping
  • the mortar nozzle 1070 At the front, hanging down from the underside of the main chassis is the mortar nozzle 1070. Above this on the top side of the main chassis is the opening 1080 through which the mortar dispenser is able to fill the mortar storage canister that is inside the main chassis 1020.
  • the two semi-circular objects that form the opening slide along the rectangular objects either side to reveal an opening.
  • the nozzle 1070 on the underside is able to extend, rotate about a vertical axis, and apply the mortar to the area of the wall where the brick is to be placed.
  • Figure 56 illustrates an example of a robot 56100 that is capable of performing all the most rudimentary actions to build a simple brick structure in the case of a ramped environment.
  • the robot 65100 comprise a main chassis 56110 that sits atop a track set 56120 comprising a single pair of tracks. Each of these tracks move independently allowing for differential drive steering. A double trackset may also be used to provide more manoeuvrability.
  • At the front of the main chassis is an opening from which mortar may be extruded using an internal pump/archimedes screw or other such mechanism. By extruding mortar and driving the tracks, forwards or backwards, mortar can be spread onto horizontal surfaces and allowed to pile up against vertical surfaces.
  • On top of the chassis is an opening which allows the mortar container to be filled.
  • a linear joint 56140 which enables the robot arm, attached at the top of this joint, to be moved up and down vertically.
  • simple gripper 56130 comprise a linear joint and two clasps.
  • the gripper linear joint changes the size of the gap between the two clasps enabling the gripper to grip bricks/blocks or other attachments such as the pointing tool. Additional degrees of freedom may be added to control the brick placement (horizontal motion of the gripper, rotation, pitch and yaw of the brick).
  • the robot 56100 is able to pick-up and place bricks at the same level or the level above. It may also pick-up and place ramps, enabling it to drive from one level of the structure to another.
  • Figure 57 illustrates the robot 57100 in situ, about to place a brick onto a bed of mortar.
  • the mortar has been laid by the robot by driving up to the adjacent brick and extruding mortar as it drives away to its current position. To place the brick the vertical arm will be lowered onto the mortar bed.
  • the robot may comprise an effector and a means for traversing and/or climbing the structure under construction.
  • the effector is configured to releasably couple to a structural unit.
  • the effector is configured to move along a single axis, and more preferably the single axis is the vertical axis.
  • the robot comprises at least one track set.
  • the robot comprises two track sets.
  • the means for traversing and/or climbing may be legs and feet as described herein.
  • the means for traversing and/or climbing may also be legs and feet where the feet have track sets on the end.
  • the track set of the robot may be located at the bottom of the body of the robot.
  • the robot may comprise a foot coupled to the robot body.
  • the robot’s track set may be coupled to the foot.
  • the track set may comprise two tracks.
  • the speed of each of the tracks within the track set may be independently controlled.
  • the robot is able to rotate and/or turn.
  • the robot can turn on a point.
  • the robot can turn on a point with any number of track sets.
  • Two vertical joints may be used control the relative heights of two sets of tracks.
  • Each track set may be able to rotate on a vertical axis, and may also vary relative the speeds of each track (differential steering).
  • Each track set may be the width of one brick.
  • the tracks may be dimensioned and spaced apart such that they have the longest overall wheel base whilst also being able to fit onto the length of one brick, and also rotate independently of one another whilst not clashing.
  • the robot may comprise a further track set.
  • the two track sets may be dimensioned and spaced apart such that they are able to fit onto the length of a single structural unit.
  • the two track sets may be dimensioned and spaced apart such that they each can rotate independently of the other whilst not obstructing the each other.
  • the robot can turn on a point by raising either of the track sets off the ground while the other remains.
  • the track set(s) of the robot may be coupled to the robot body by a length adjustable leg (or legs if two are present) such that each track set can be raised or lowered independently.
  • the movement of the legs is along a vertical axis.
  • the legs may be similar or the same of the legs as described with reference to the robot without tracks.
  • the legs may be different in that they can only be adjusted vertically.
  • the robot further comprises a main effector, such as an end effector.
  • the main effector may be a main gripper.
  • the main gripper is configured to grip structural units, such as a brick.
  • the main gripper moves horizontally along the main chassis independently of the two legs. It is mounted on the underside of the chassis, between the paths of the two legs.
  • It has a clasping mechanism (for example, a set of jaws) which can open or close to grip and hold a structural unit.
  • the clasping mechanism grips the long outer edges of the structural unit.
  • the same clasping mechanism may be used to hold structural units of different widths by opening and closing the clasping mechanism according to the width of the brick to be held. If perforated or frogged structural units are being used, the main gripper may also hold the structural unit from the inside.
  • Figure 8 shows a perspective view of the exposed workings of an exemplary robot gripper 82040, shown clasping a typical brick 82090.
  • the mechanism is composed of a main plate 8250, which is approximately square. This is joined to the rest of the robot’s mechanism via a bearing joint 8260 which allows the whole gripper assembly to rotate around the vertical axis. A central hole within this bearing allows wires to pass to the rest of the gripper mechanism while it rotates.
  • a linear actuator is mounted in the middle of the plate 8270, controlling the movement of the two gripper jaws 8050-1. The jaws can move horizontally in a linear motion, moving closer together or further apart.
  • the jaw ends consist of a vertically mounted flat plate 8050-1 which interfaces with the side of the brick.
  • the plate may have a shaped or stepped end profile to allow it to also interface with the top of the brick, thus calibrating the brick’s vertical and lateral position.
  • a sensor see figure 9 to measure distance between the top of the brick and the plate.
  • tapping or vibration mechanisms 8280 Arranged in symmetrical pairs, there are tapping or vibration mechanisms 8280 to adjust the relative position of the brick once it has been placed on to the mortar bed and released from the gripper jaws.
  • Each mechanism consists of a motor 8290- 9 with an eccentric mass attached to its shaft.
  • a Linear Resonant Actuator type vibration motor may also be used.
  • the motor assembly is mounted on a linear element, connected at one end with a hinge joint to the main plate.
  • the linear element At the end of the linear element is a shaped, dense, and hard- wearing element to allow good transfer of force to the brick, like a hammer head 2300-9.
  • the eccentric mass induces the linear element to move through its arc of motion when tethered by the hinge joint.
  • At one end of the arc it may be supported by a spring restriction to increase the return force.
  • At the other end of the arc it makes contact with the surface of the brick, transferring a high impact force.
  • the tapping mechanisms may be brought into tapping range of the brick by widening the gripper jaws to allow the main plate to be lowered.
  • the tapping mechanisms are mounted such that they can deliver impacts to the brick edges from each side and from the top. In the example shown, there are two on each brick side edge, two on the end, and four to affect the forces to the top of the brick.
  • the gripper can be moved around by the robot’s other degrees of freedom such that the exact impact locations of these mechanisms can be finely tuned.
  • a control program interprets the distance sensors in combination with other sensors on the main robot body such as cameras, LIDAR, accelerometers etc. to determine which tapping mechanism should be applied, where precisely on the brick it should be applied, and how large the impact force should be.
  • Figure 9 shows a perspective view of the underside of the exemplary robot gripper 9040, shown without a brick in place.
  • This shows the aforementioned elements: the flat underside of the main plate 9250, with a distance sensor 9310-9 in each comer pointing downwards towards the brick face.
  • the gripper jaws 9050-1 are free to move horizontally, and feature a shaped or stepped end profile to interface with the sides and top of the brick.
  • the linear elements of the tapping mechanisms with their respective end pieces are allowed to access the brick from the sides or top.
  • the effector may have only one degree of freedom.
  • the movement of the effector is optionally only in the vertical axis.
  • the vertical axis may be defined as perpendicular to the primary direction of movement.
  • the vertical axis may be defined as perpendicular relative to the body of the robot which extends primarily in a horizontal axis.
  • the vertical axis may be defined as vertical relative to the ground when the robot is resting flat on the ground.
  • the vertical axis may be considered up and down relative to a major axis of the body of the robot.
  • the vertical axis may be considered up and down relative to the structure being assembled.
  • the effector may have two degrees of freedom: vertical and rotation about the vertical axis.
  • the further degree of freedom of the effector means the robot will not have to align the body of the robot up directly with the structural unit about to be gripped.
  • the relative rotation of the structural unit to the robot no longer matters as the effector can rotate itself instead of rotating the body.
  • further degrees allows for more complex gripping situations of the robot and therefore reduce the amount of manoeuvring of the robot relative to the structural unit.
  • the effector may have additional degrees of freedom to control the roll and pitch of the structural unit.
  • the robot may include a connecting material storage and delivery system.
  • the connecting material storage and delivery system is sized appropriately to store at least enough connecting material to lay a single brick.
  • the connecting material storage and delivery system comprises a connecting material container attached to the robot body.
  • the connecting material container is connected to a section comprising a shaped opening.
  • the section comprising a shaped opening is referred to herein as a nozzle.
  • the connecting material container may include a second opening for filling the connecting material container, however in some embodiments the connecting material container is filled via the nozzle.
  • the connecting material storage and delivery system comprises a cylindrical connecting material container mounted vertically within the robot body.
  • the connecting material container comprises an opening in the top and a shaped opening in the bottom (the nozzle).
  • the nozzle may be detachable element (e.g. a snap or screw fitting), that is detachable from the remainder of the connecting material storage and delivery system, to allow nozzles with various shapes to be fitted to the connecting material storage and delivery system.
  • This provides for shaping of the connecting material into different application shapes as the connecting material exits the nozzle as required for different brick types. This may also allow easy assembly, maintenance and cleaning of the nozzle and connecting material storage and delivery system.
  • the nozzle opening may be angled to allow connecting material exiting the connecting material storage and delivery system to adhere to both horizontal and vertical surfaces. In a preferred embodiment, the nozzle opening is angled at 45 degrees.
  • An example application shape for the connecting material is a rectangle slightly taller and slightly narrower than the final volume of connecting material once it is in place with a brick on top of it. This application shape allows the connecting material to be compacted into final position, generating good surface adhesion, without creating large excess needing to be cleaned up afterwards during pointing.
  • the connecting material is mortar
  • this system greatly reduces the amount of mortar used when compared with traditional methods of brick laying wherein the mortar is placed on the structure by hand.
  • Alternative shapes may also be used, such as a rectangle with rounded comers, a cylinder, or a rectangle with V-shaped projections.
  • the nozzle may have a nozzle cover which covers the opening of the nozzle.
  • a flap or a set of flaps, which cover the opening of the nozzle.
  • This nozzle cover allows the connecting material storage and delivery system to build up pressure behind the nozzle cover, such that the connecting material may then be released in a smooth stream.
  • the nozzle cover could be passive e.g. spring loaded, or active e.g. controlled by an actuator.
  • the top of the connecting material container may be covered by a moveable cap.
  • the moveable cap may be opened by the application of force to the moveable cap.
  • the force may be applied by an actuator within the robot.
  • the force may be applied using something outside the robot - for example, the force may be applied by the robot pushing itself into something, or by something pushing itself into the robot.
  • the moveable cap may be closed by the application of force. Again, the force may be applied by an actuator within the robot, or something outside the robot.
  • the moveable cap may be spring loaded to snap shut after the force which opened the moveable cap is released (e.g. the cap is a like a sliding door with sloping tops, or a trapdoor which opens downwards).
  • the moveable cap is configured to open when a vertical force is applied to the cap.
  • the robot is configured to ‘crouch down’ with the moveable cap positioned underneath the nozzle of a connecting material supply point and then ‘stand up’, thus interlocking the nozzle of the connecting material supply point with the opening of the robot’ s connecting material container.
  • the connecting material supply point may then supply the robot with connecting material.
  • this mechanism is an auger screw which is sized to fill a cylindrical connecting material container. As it turns (powered by a motor), it pushes connecting material down the container and expels it out the end, under pressure and at a controllable rate.
  • a piston which moves down the length of the tube and similarly expels the connecting material under pressure and at a controllable rate.
  • the connecting material storage and delivery system may comprise a Connecting material flow control system which controls the flow of connecting material from the nozzle.
  • the flow control system improves the accuracy of the flow of connecting material from the nozzle by measuring the flow of connecting material from the nozzle and adjusting the mechanism for pushing connecting material through the nozzle.
  • the flow control system comprises sensors are used near the nozzle opening to determine the rate of connecting material flow.
  • the sensor may comprise a flow-meter, such as an optical flow-meter or a paddle wheel meter to measure the flow.
  • sensing can be avoided by calibrating the system which pushes the connecting material through the nozzle.
  • an archimedes screw may control the rate of flow.
  • the nozzle may be configured to rotate around a vertical axis. This allows the end of the nozzle to be controllably positioned such that when the connecting material exits the nozzle, it can be applied to the vertical faces of the structural units already in place to the side(s) of the intended location of the structural unit to be placed.
  • the nozzle may be configured to move horizontally relative to the robot body in order to apply connecting material along the horizontal top surface of the structural unit below the intended location of the structural unit to be placed.
  • the number of moving parts may be reduced by fixing the horizontal position of the nozzle relative to the robot body, and configuring the robot to move its body, and thereby the nozzle, horizontally in order to apply connecting material along the horizontal top surface of the structural unit below the intended location of the structural unit to be placed.
  • the nozzle may not extend vertically from the robot body as far as the legs when the robot is body is in its tallest position such that the nozzle is clear of the structure when the robot manoeuvres around the structure.
  • the robot is configured to lower its body, and thereby the nozzle, towards the structure when applying connecting material.
  • the nozzle may be configured to move vertically relative to the robot body.
  • a robot may use both methods.
  • the connecting material storage and delivery system may have a depth sensor or other sensor to assess how much connecting material the system currently contains. This can inform the robot as to the amount of mortar required to refill the connecting material storage and delivery system for the next given brick to lay, and the length of time required for refilling.
  • the robot control program may be configured to adjust the amount of connecting material required depending on the brick type and position in the structure.
  • the connecting material storage and delivery system may include at least one sensor for checking the moisture content of the connecting material.
  • the robot may alert the controller if the mix is not correct.
  • the robot may add water from an onboard reservoir as required.
  • the robot may also comprise a reservoir for storing an additional chemical, such as a catalyst agent, which is added to the connecting material just as the connecting material is expelled from the nozzle, to make the connecting material set more quickly.
  • the robot may use a mechanism to mix the connecting material within the connecting material storage and delivery system. This may be a single or multiple rotating paddle wheels located within the container. Alternatively, the connecting material may be passed through a series of fins or constricted openings to passively mix the connecting material.
  • the connecting material storage and applicator unit may be mounted on the same end of the robot as the effector.
  • the connecting material storage and applicator may comprise a hollow container with nozzle opening at the lower end through which the connecting material is delivered.
  • the whole unit may be able to move vertically and rotate in the vertical axis to allow connecting material to be applied to vertical and horizontal surfaces (when combined with a horizontal movement of the robot on its tracks), and also to be able to store the unit inside the chassis when not in use (important for allowing the brick to be placed underneath).
  • the unit may use a screw or in this case a piston (with a tight seal with the inside of the container) to drive the connecting material out.
  • the container may be filled with connecting material by submerging the nozzle in connecting material and moving the piston vertically to draw the connecting material upwards by suction.
  • the container may be filled from the top, by raising the piston above an entry point to the container, putting connecting material into the container, then lowering the piston past the entry point.
  • the container may be oscillated or agitated using the available degrees of freedom (e.g. rotating the container in the vertical axis) to encourage shear thinning of the connecting material thereby enabling it to flow more easily.
  • other connecting material applicators may be used such as rollers, or adhesive may be used instead (in the case of thin-bed joint blocks).
  • the nozzle may have a specially designed pointing device for pointing the connecting material after the structural unit has been laid.
  • the pointing device may include a pointing element integrated into the form of the nozzle or be a separate detachable and interchangeable pointing element.
  • the use of separate detachable and interchangeable pointing elements allows for different pointing styles such as square inset, raked, rounded etc.
  • the robot may move the nozzle through a motion similar to that performed when applying connecting material, but in this case extend the nozzle and scrape the pointing element along the external facing surface of the connecting material joint.
  • the excess connecting material may be scooped up into a temporary storage point built into the nozzle. Alternatively, the excess connecting material may be deliberately scraped off and encouraged to fall to the ground.
  • the nozzle may have brush element attached to it e.g. on the reverse side of the nozzle. This allows the robot to brush the face of the newly laid brick and do a final clean-up of the connecting material after it has been pointed.
  • the robot may be configured to move the nozzle in a similar way to the way the robot moves the nozzle when it applies the connecting material, but this time it reaches down the outside of the new brick which has been laid and passing the brush element along the connecting material bead.
  • the connecting material may be prepacked into cartridges of appropriate size. These cartridges may hold the connecting material within a single use or reusable container, for example made from a thin plastic film.
  • the cartridges are loaded into the storage and delivery system as sealed units. They may then be squeezed under pressure to puncture the cartridge and expel the connecting material from the nozzle.
  • the cartridge may employ a valve to interface with the connecting material storage and delivery system. This would allow the connecting material to flow from the cartridge only after the valve has been opened by the storage and delivery system.
  • Figure 4 shows a perspective view of an example connecting material storage and delivery system 4100.
  • This consists of a hollow cylinder 4110 in which the connecting material is stored, here shown with a cutaway view.
  • a cap 4120-1 at the top of the cylinder allows connecting material to be poured in through an opening 1080.
  • the cap 4120-1 is shaped with an indentation such that when a force is applied to it from the top, for example by a round tube seeking to enter the hole, then the sides of the cap are pushed apart to reveal the opening.
  • the moveable pieces of the cap 4120-1 move along rails 4130-1 and are pushed back by springs, such that when the tube is removed from the opening, the cap automatically springs back shut.
  • a mounting point 4140 by which the cylinder is attached to the main robot chassis.
  • This mounting point may be moved vertically or rotated, such that the whole cylinder can be lowered from the robot and rotated to direct the flow of connecting material from the nozzle.
  • a motor 4150 which is connected to a rotating shaft 4160 contained inside the hollow cylinder, using a mechanical linkage such as a belt.
  • the shaft is connected to an auger screw 4170, sized to abut the edges of the cylinder.
  • a flow sensor in the mouth of the nozzle see Fig 5 5200, combined with changing the auger’s speed of rotation allows the connecting material flow to be controlled.
  • FIG. 5 shows a perspective view of an example nozzle 5070 fitting attached to the end of the connecting material container cylinder 5110. It shows the main body of the cylinder, with a depth gauge sensor 5180 to signal the level of connecting material left in the container.
  • the nozzle assembly attaches to the cylinder using a screw or snap fitting 5220-1, to allow cleaning, maintenance or alternation of nozzle shape.
  • the nozzle opening is rectangular, at 45 degrees to the vertical plane, to allow adhesion of the dispensed connecting material to vertical and horizontal surfaces.
  • a flow sensor 5200 mounted near the nozzle opening allows monitoring of the current rate of connecting material flow. At each side of the nozzle, there are additional fittings to allow pointing of the connecting material.
  • This example shows a curved projection, proportioned so that when it is passed across the connecting material joint of a freshly-laid brick, it leaves a desirable concave pointing style.
  • a different fitting could be designed to give straight or angled pointing style.
  • These fittings are detachable e.g. by snap fit or threaded connection, so they can be easily cleaned or changed.
  • On the rear of the nozzle there is a brush fitting. This is designed to allow the pointed connecting material joint to be brushed free of small flecks of connecting material as is customary.
  • the brush attachment may also be snap fit to allow easy maintenance.
  • Figure 13 shows twelve diagrams illustrating the intermediate configurations of the exemplary robot during the brick placement action. The illustrations are ordered from left to right, starting at the top and working down.
  • Frame 1 shows the starting configuration of the robot standing on the brick structure in front of the area where the brick is to be placed.
  • Frame 2 shows the extended nozzle ready to spread the connecting material.
  • Frame 3 shows the starting position for the connecting material spreading where the main chassis of the robot has been lowered and moved backwards to put the connecting material nozzle in the lower right hand corner of the brick placement region.
  • Frame 4 shows the end of the first connecting material spreading action. The main chassis of the body has been raised, lifting the connecting material nozzle as the connecting material is pumped out, spreading a layer of connecting material on the head of the brick next to the placement region.
  • Frame 5 shows the starting position for the next phase of connecting material spreading.
  • the main chassis of the body has moved forward in front of the connecting material already spread in the previous phase as well as lowered to its starting position.
  • Frame 6 shows the final robot configuration after the connecting material spreading.
  • the main chassis has been moved forward as the connecting material nozzle extrudes connecting material over the area where the brick is to be laid.
  • Frame 7 shows the robot in its starting configuration as was shown in Frame 1.
  • the nozzle has been retracted and the main chassis raised and pulled back.
  • Frame 8 shows the robot configuration just before laying the brick.
  • the gripper has moved forwards to place the brick above the region where it is to be placed.
  • Frame 9 shows the configuration of the robot as the brick is placed.
  • the main chassis has been lowered with respect to the legs putting the brick on top of the connecting material.
  • Frame 10 shows the robot returning to its configuration having placed the brick.
  • the gripper has released the brick in its position, making all necessary finer adjustments to the bricks position using the tapping and sensing mechanism, and has raised the main chassis back to its walking height.
  • Frame 11 shows a diagram of the configuration of the robot during pointing.
  • the rear leg has raised, allowing the main chassis of the robot to be rotated so that the connecting material nozzle with its pointing attachment can reach the side of the brick.
  • the main chassis is then able to move back and forth, whilst rotating, brushing the side of the brick and removing any excess connecting material.
  • Frame 12 shows the robot returned to its initial configuration, with the brick placed.
  • Figure 10 is a diagram of the exemplary robot 10000 configuration just after it has spread the connecting material for a brick 10090 to be laid.
  • the robot is located on top a brick structure.
  • the nozzle 10110 is extended and the main chassis 10020 is lowered so that the head of the nozzle is positioned just above the area where the connecting material is to be spread.
  • the brick 10090 is clasped in the gripper waiting to be placed.
  • the connecting material can be seen already spread on top of the brick structure in the region where the brick is to be placed.
  • Figure 11 is a diagram of the exemplary robot 11000 configuration just before placing a brick 11090 on a brick wall.
  • the connecting material is illustrated spread over the region where the brick is to be placed.
  • the gripper is positioned over this region with a brick clasped between its jaws.
  • Figure 12 is a diagram of the robot configuration as it places the brick in the connecting material.
  • the main chassis 12020 has been lowered such that the brick is placed on top of the connecting material bed. It is at this point that the tapping mechanism in the gripper makes final adjustments to the bricks position, once the jaws of the gripper have been released. This detail is not shown in the diagram.
  • the robot may comprise a pointing tool.
  • the pointing device may be separate from the nozzle entirely and be removable/detachable from the robot.
  • Figure 44 illustrates an attachment that can be picked up by a robot gripper and enables the robot to point the mortar beds of the laid bricks.
  • the top of the attachment is a square block 4410 of a similar width to the bricks and blocks being used for construction.
  • Two rectangular protuberances on either side of the solid block comprise a high friction surface that assists the robot’s grip. These may also comprise mechanical devices to produce a stiff connection when clasped by a gripper.
  • a passive arm 44200 extends down on one side from the lower end of the block 4410. It extends outwards away from the block 4410 and returns to be flush with the block 4410 at the lowest end of the arm 44200.
  • the very end of the arm 44200 is shaped to provide the desired pointing finish. In this case it is a curved surface to provide a shallow pointing finish, but may comprise a semi-sphere or cone for deeper pointing finishes. This end may be detachable, to allow easy changes of pointing style.
  • a similar tool may be used for any number of other functions associated with brick or block laying. E.g. brushes for sweeping dust and flecks of dry mortar; paint dispensers for coating the brick wall in paint as it is built; a nail gun or screwdriver for attaching wall ties; a separate gripping device for manipulating insulation boards.
  • Figure 45 illustrates the pointing attachment in use.
  • the robot gripper is clasped to the square block 45100 at the top of the pointing attachment, with the clasps of the gripper positioned on top of the rectangular protuberances that assist the grip.
  • the block can be considered the body of the pointing device.
  • the center of the gripper is positioned above the centerline of the brick wall which places the end 45200 of the pointing tool in position up against the mortar bed and flush against the side of the brick wall.
  • To perform the pointing action of the gripper of the robot is moved vertically and horizontally along the axes of the robot arms joints 45300 such that the end 45200 of the pointing tool traces the path of the mortar beds, removing any excess mortar.
  • the pointing tool may have fiducial markers attached that enable the robot to easily identify and track its position and orientation.
  • the pointing tool may be stored in or on the robot. Alternatively, it may be stored in a specially designed tool rack, within reach of a robot at some point on its journey around the structure. In this scenario, a layer (or number of layers) of bricks may be laid, then a robot or several robots may go around the structure doing all the pointing in one go.
  • the assembly system for assembling a structure out of a plurality of structural units may comprise a tool; and a robot configured to grasp the tool.
  • the tool may be a finishing tool for finishing the connecting material after a structural unit has been laid.
  • the structural unit may be considered laid when the structural unit is connected to another structural unit by the connecting material.
  • the tool may be a pointing device for pointing the connecting material after a structural unit has been laid.
  • the tool may comprise a body and an arm extending from the finishing tool body, preferably such that in use the robot may position the end of the finishing tool arm flush with the structural units connected by the connecting material to be finished.
  • the finishing tool arm may be generally c-shaped.
  • the finishing tool arm may comprise a shaped tool for finishing the connecting material to provide a desired finish, and optionally, the shaped tool is removable from the remainder of the finishing tool arm, or the finishing tool arm is removable from the finishing tool body.
  • the tool may also be any one or more of the following: a brush, a paint dispenser, a dustpan, a nail gun, a screwdriver, a ladle, and/or an insulation board manipulation device.
  • the robot may comprise an effector configured to releasably couple to a structural unit and/or the tool.
  • the coupling may be only one at a time such that the robot can only pick up either a tool or a structural unit at any given time.
  • the coupling may instead by at the same time such that the effector comprises further gripping means to grip both the tool and the structural unit at the same time.
  • the robot may comprise a wall tie applicator.
  • the wall tie applicator comprises a small wall tie gripper mounted on the rear of the connecting material nozzle or on a leg or the main gripper.
  • the wall tie gripper can clasp and rotate wall ties.
  • Wall ties are configured to be attached to an inner structure. For example, by drilling or nailing them into the inner structure.
  • the wall ties are configured to fit into extruded metal U-sections attached to the inner structure.
  • the wall ties may be inserted into the U-section while in the vertical plane.
  • the wall ties may interface with the U-section such that once the wall tie is inserted, it cannot be removed.
  • the wall tie may comprise teeth that engage with a pawl in the U-section to form a ratchet, so that as the end of the wall tie is inserted in the U- section, it cannot come undone.
  • the wall tie may be rotated to latch into the U- section.
  • the wall ties may have small notches to interface with the U-section.
  • the assembly system comprises a dedicated‘wall tie’ robot, which emphasizes in attaching wall ties.
  • the dedicated wall tie robot comprises a specialised wall tie effector for the main effector, in place of the main gripper, which is configured to store and manipulate wall ties, and be able to place, drill, and/or nail them into an existing inner structure.
  • the robot may comprise a charging point for charging the robots battery.
  • the charging point may be configured to allow for an automated charging at a charging station.
  • the charging may be contactless through induction.
  • the charging point may be on the robot body.
  • the charging point may be integrated into the robot’s feet to allow charging by standing the robot on a certain point (or charged continuously as it walks over certain parts of the structure such as the staircase explained below).
  • the robot may also have other sources of power such as solar panels.
  • a cover may be used to protect them from moisture or dirt.
  • this cover may be actively moved by an actuator, or passively pushed aside by the robot, so as to expose the contacts to the charging station.
  • Figure 32 shows an example of a unit designed to allow the robots 32000 to charge their batteries autonomously 32960. It consists of a number of docking stations mounted on a single unit 32970, although these docking stations could also be separated into distinct units themselves. It may have a carry handle or wheel to allow easy transportation.
  • This single unit is a portable structure containing a computer controller and means to dispense electrical power to the robots’ batteries. It may have larger internal batteries, or be connected to an external power source 32980 such as a solar panel, wind turbine, or generator etc., or mains power cable 32990.
  • the solar power and mains power cables are illustrated in the diagram.
  • the unit has male elements which engage with the robot’s batteries, with contact or induction charging capabilities.
  • Pathways 32240 for the robot consisting of a designed surface suited to interface with the robot’s foot allow the robot to approach the connection points on the unit. These pathways are connected or placed next to robot’s main work area to allow easy access. The pathways may have virtual checkpoints to communicate with other robots that a certain charging bay or pathway is occupied.
  • the robot can hook its battery onto the male element on the unit and allow it to charge.
  • the robot may uncouple from the battery and leave it charging.
  • the robot can then proceed using the designed pathways to another available battery on the unit, which has been previously charged.
  • the robot may be powered during this intermediate time, while it has no main battery connected, using another internal battery, or contact or induction power via its feet on the pathways.
  • the robot s various degrees of freedom (position and rotations of legs, gripper, nozzle and chassis) are controlled and coordinated by the robot control program such that the overall system is always balanced.
  • the robot knows what type of structural unit and how much connecting material it is carrying at any given time, so adjusts its balancing to suit. For example, when taking a step, the robot control program arranges the robot body and main effector so the centre of mass is over one leg; then it lifts the other leg; then it moves the raised leg past the stationary leg whilst the robot body and/or main effector are moved in the opposite direction at the required speed and acceleration to maintain a net zero jerk force on the robot; then it places the leg down and repeats to take another step.
  • each motor has at least one rotary encoder attached to its output shaft. This allows the position, speed and acceleration of the shaft to be determined at any point in time. This allows a Proportional Integral Derivate (PID) control algorithm to be implemented.
  • the motor’ s encoder may be connected to a central controller, or to a decentralised controller for each motor. In the decentralised case, a central controller may give only top-down commands to each motor, and each motor controller implements the PID algorithm to achieve the desired result.
  • Net zero jerk force is maintained by treating each primary component of the robot assembly as a movable mass.
  • the main beam may weigh 5kg, and each leg may weigh 1kg, and the gripper may weigh 3kg. If the gripper stays in the same place relative to the main beam (e.g. during a typical step), the total mass of the main beam and the gripper would be 8kg.
  • Using these component weights we can take the example of a robot balanced over one of its legs, leg A.
  • the other leg, leg B may, for example, have its centre of mass 8x distance from leg A on one side. In this case, for the robot to be balanced, the main beam and gripper must have their centre of mass x distance away from leg A on the other side.
  • leg B moves past leg A to be 8x distance away from leg A on the opposite side from where it started.
  • the main beam and gripper are moved such that they end up x distance away from leg A on the opposite side from where they started.
  • Figure 2 shows twelve exemplary diagrams illustrating the intermediate configurations of the robot 2000 joints during a step-up action onto a brick. The illustrations are ordered from left to right, starting at the top and working down. Each diagram shows a line of five bricks on top of which the robot is positioned.
  • Frame 1 shows the robot in a standing position.
  • Frame 2 shows the robot moving the gripper and chassis, illustrated holding a brick, move forwards so that the centre of gravity of the robot is over the front leg.
  • Frame 3 shows the robot lifting its rear leg and balancing on the front leg. Once the leg is lifted the robot moves the leg forwards, maintaining balance by moving the gripper and chassis at the correct speed in the opposite direction.
  • Frame 4 illustrates the mid-point of this manoeuvre, where the gripper, chassis, raised leg and fixed leg are aligned, balancing the robot.
  • this mid-point arrangement may be different as the mass distribution of the robot changes.
  • Frame 5 shows the configuration of the robot when the raised leg has reached the intended position ready to be placed down. Note the gripper and chassis have moved further back to compensate for the weight of the leg at the front of the robot.
  • Frame 6 in a standing configuration with the raised leg now placed down in its intended position, completing the first step.
  • Frame 7 shows the configuration of the robot after the gripper and chassis of the robot have moved forward to place the centre of mass over the front leg once again, achieving the same configuration as Frame 2 but having switched the places of the right and left leg.
  • All subsequent frames show the same configurations as for the corresponding frame in the previous stepping action but with the right and left leg switched, (e.g. Frame 8 ⁇ -> Frame 3, Frame 9 ⁇ -> Frame 4).
  • Frame 8 shows the rear leg raised, balancing the robot on the front leg.
  • Frame 9 shows a still mid-step as the raised leg moves forwards and the gripper moves back to keep the robot balanced.
  • Frame 10 shows the end of the stepping action with the raised leg above its intended placement location.
  • Frame 11 shows the robot in a standing configuration with the raised leg now lowered.
  • Frame 12 shows the final standing configuration, identical to the configuration of Frame 1 but with the robot now two brick lengths further along the brick structure it is standing on, having completed two steps.
  • a heavy mass (e.g. the battery) may be located in the main chassis.
  • the heaving mass may be able to move horizontally to change the centre of mass between each foot, leg and/or track set.
  • This heavy mass may also be integrated into the rear portion of the gripper. This heavy mass may be used in conjunction with the planned mass distribution described above.
  • Figure 3 shows twelve diagrams illustrating exemplary intermediate configurations of the robot joints during a step-up action onto a brick.
  • the illustrations are ordered from left to right, starting at the top and working down.
  • Each diagram shows a line of five bricks on top of which the robot and one other brick are positioned.
  • the frames correspond exactly to the frames described for the Figure 2 figure but with a differing final height for the leg taking the first step as it climbs on the brick.
  • the robot may comprise at least one robot balancing system.
  • the robot balance system enables the robot to balance on one foot in order to take steps and rotate. For the robot to balance correctly it needs to either know the mass distribution in the robot, which regularly changes, or use sensors to detect when it is off balance and adjust dynamically.
  • the planned mass distribution method (previously described) may be used as a coarse grain method, with a sensor method used to fine-tune or safeguard the robot’s balance in finer detail.
  • Three exemplary robot balance systems for ensuring the robot is balanced using sensors are described below.
  • the robot may comprise a pressure robot balancing system.
  • a pressure robot balancing system comprises pressure sensors in the four comers of the feet of the robot. If the robot is correctly balanced and the surface the robot is standing on is flat, then the pressure at all four comers of the foot of the robot should be equal.
  • the pressure robot balancing system comprises a control loop which monitors the pressure at a plurality of points on the robot - for example, the at the feet of the robot - and controls the position of the main effector to continually balance the robot. By monitoring the pressure at, for example, the robot’s feet, the pressure robot balancing system can quickly adjust the position of the main effector to minimise the difference in values reported by the pressure sensors.
  • the robot corrects by moving the gripper or effector along the main beam in the direction of decreasing pressure.
  • the speed and exact manner of the response by the gripper are controlled by, for example, a PID controller.
  • the robot may comprise a strain robot balancing system.
  • a strain robot balancing system comprises strain gauges - for example in the legs and main beam of the robot - which can be used to detect bending and flexing that will occur as the robot tips.
  • the strain robot balancing system comprises a control loop configured to monitor the strain gauges and control the position of the main effector to continually balance the robot.
  • the control loop may be configured to minimise strain. For example, for a robot with strain gauges in its legs and arranged in a pose such that it is standing on one leg, if the strain robot balance mechanism detects a strain in its standing leg in a particular direction it corrects by moving the effector or gripper in the opposite direction, thereby reducing the strain.
  • the speed and exact manner of the response by the gripper are controlled by, for example, a PID controller.
  • the robot may comprise a gyroscopic robot balancing system.
  • a gyroscopic robot balancing system comprises at least one gyroscopic sensor to detect changes in angular momentum. Certain changes in angular momentum indicate that the robot is losing balance. When the gyroscopic robot balancing system detects such changes in angular momentum, the robot adjusts the position of the main effector to balance the robot.
  • the gyroscopic robot balancing system comprises a control loop configured to monitor changes in angular momentum and control the position of the main effector to continually balance the robot.
  • the gyroscopic robot balance system detects a tilt in a particular direction along the axis of the main beam it corrects by moving the effector or gripper in the opposite direction, thereby reducing the detected tilt.
  • the speed and exact manner of the response by the gripper are controlled by, for example, a PID controller.
  • control loops of the robot balancing systems may also be configured to control the position of other parts of the robot to maintain balance. For example, the position of the main beam or the spatial arrangement of connecting material within the connecting material container.
  • control loops of any robot control system may use proportional, integral, and/or differential control.
  • the robot may include at least one collision avoidance system.
  • the collision avoidance system detects potential collisions. Upon detection of a potential collision, the robot will pause before calculating evasive or alternative actions. Two exemplary collision avoidance systems are described below.
  • the robot may include a proximity collision avoidance system.
  • a proximity collision avoidance system proximity sensors placed at key points along the main beam of the robot. Since all joints of the robot move relative to the robot body, all collisions can be avoided by ensuring that the areas around the robot body and the space below it are free from obstructions.
  • a LIDAR sensor scanning in a plane perpendicular to the robot body is able to detect potential obstructions as the robot manoeuvres around, covering the area beneath the main beam.
  • the proximity sensors ensure the robot body avoids collisions by pausing the robot actions if the values fall below a safety threshold.
  • the robot may include a stereoscopic collision avoidance system.
  • a stereoscopic collision avoidance system may comprise two stereoscopic wide-angle cameras, one facing a first direction of robot travel, and the other facing the opposite direction of robot travel.
  • Using stereoscopic vision enables a depth-map to be obtained for the areas within the camera's field of view. Using the depth-map, distances to objects are obtained and threshold values can be set below which the robot can pause operations to avoid collisions.
  • Stereoscopic cameras have the added benefit of being able to detect and identify particular environmental objects, e.g. humans, and adopt larger safety thresholds to take into account the behaviour of the detected object, e.g. unpredictable human behaviour, ensuring greater safety.
  • the automated assembly system may comprise assembly control program.
  • the assembly control program orchestrates the robots.
  • the assembly control program may control each robot by configuring each robot’s individual robot control program before each structure is assembled.
  • the assembly control program may control the robots by continually communicating with each robot’s individual robot control program during the assembly process.
  • the key input to the robot organisation program is a model of the design of the structure that is to be built.
  • the construction industry has recently adopted Building Information Modelling (BIM) as the standard method for designing and digitally representing buildings.
  • BIM Building Information Modelling
  • BIM models of buildings typically represent brick structures by their dimensions, e.g. height, width and depth, including the dimensions of cut-out regions for windows etc.
  • a structural unit layout model is generated from the BIM specifications.
  • the structural unit layout model provides a plan including the 3D location and orientation of each structural unit in the structure.
  • the structural unit layout model may provide the position and orientation of each complete brick and each cut-brick, the total number of bricks required, and the total number of courses.
  • the robot organisation program may calculate the build-time and costs for assembling the structure as a function of the number of robots and different material supply locations.
  • Optimal solutions can be computed by defining the available space on-site around the structure, which may constrain the possible material supply locations.
  • the state of the structure at all stages of the assembly process is determined by the assembly control program, such that the structure is always traversable with the robot’s capabilities. For example, if a robot is only capable of stepping up or down the height of one structural unit, then the assembly control program plans the assembly process such that there is no need to make a robot step up or down more than the height of one structural unit.
  • the assembly control program may determine the number of robots and additional hardware required for assembly. Alternatively, the assembly control program may determine the assembly process constrained by the number of robots and/or the use of certain additional hardware.
  • the structural unit layout model can be recomputed late-on into the build process. If the as-built structure deviates from the BIM design (e.g. due to mistakes being made or late design changes), these deviations can be taken into account and all the above mentioned properties can be recomputed.
  • This process can be automated using 3D sensing technology, such as LIDAR, and machine learning algorithms to match the sensed 3D data, such as point-cloud data, to the corresponding BIM components.
  • 3D sensing technology such as LIDAR
  • machine learning algorithms to match the sensed 3D data, such as point-cloud data, to the corresponding BIM components.
  • By scanning the as-built structure real world measurements can be compared to the BIM design.
  • By updating the BIM model with as-built dimensions any necessary change to the brick arrangement due to deviations from the design can be computed. In this way the robot organisation program is able to control the robots to make adjustments to the structure in a way that human bricklayers routinely do.
  • FIG. 18 illustrates at a high level the software process taking a BIM model design of a structure all the way through to the actions of the robot.
  • the BIM analysis flow diagram on the left illustrates the process of extracting the information required by the robots from the BIM model. Starting with a BIM model as input 18410 as well as extra information about the brick type and the bond type, i.e.
  • the software calculates the position and orientation of each brick 18420. This can be done automatically by comparing the dimensions of the chosen brick type to the region of space they must fill as dictated by the BIM model. By adjusting the connecting material gap and the brick sizes e.g. cut or full, the software can find the optimal arrangement to fill the required space.
  • the next step calculates the optimal number of robots, supply material arrangement and equipment 18430 based upon the structure and the number of bricks as calculated in the previous step. This can be augmented with extra information, such as available space around the build site and desired costs/time constraints.
  • the software calculates the necessary flow control for the robots, such as valves and checkpoints. The valves and checkpoints may ensure an efficient and safe building process 18440.
  • the diagram then illustrates that the information calculated from this analysis is passed on to the robot 18450.
  • the high level control loop for the robot is illustrated in the“robot analysis”.
  • the initial step is deciding upon the next action depending on the state of the robot and the state of the buildl8460 18470. Once this action has been decided the joint movements for the action are calculated 18480. These could be the joint movements for stepping to the location on the build site that the robot is required to reach or the actions for placing a brick etc.
  • the robot takes into account any movement restrictions imposed by valves that control the robot flow 18490. Once these are calculated the joint movements are iterated through one by one, each time checking for collisions and checkpoints 18500 18510. If it is safe to proceed the joint movement is carried out and this repeats until the action is complete.
  • Each robot may comprise at least one positioning system which determines the global position of a feature of the robot.
  • the robots may have multiple positioning features so that if one fails there is always a back-up system. From the global position of the positioning feature, the position of each component of the robot can be determined by determining the relative position of the robot components with respect to the positioning feature.
  • the robots movements may be calibrated such that even after the robot has moved, using knowledge of the movements made the robot can determine the relative position of the robot components with respect to the positioning feature.
  • the robot may include a motive positioning system for determining the robot’s position on the structure.
  • a motive positioning system calculates a change in the robot’s position based upon the movement of the robot. The distance and direction of each robot step will be accurate to within the margin of error associated with the precision of the joint movements. From a known starting position, the robot’s position on the structure can be computed from the series of actions of the robot.
  • the robot may include a count positioning system for determining the robot’s position on the structure.
  • a count positioning system comprises a sensor for detecting the structural units around the robots feet.
  • a LIDAR sensor configured to scan the bricks around the robots feet.
  • the LIDAR sensor may be positioned such that it scans in a circle perpendicular to the directions in which the robot manoeuvres when traversing the automated assembly system, for example.
  • the LIDAR sensor may be positioned, for example, on the front of the robot.
  • As the robot manoeuvres it builds up a 3D model, such as a point cloud dataset, of the structural units, such as bricks, structure, and/or other components of the automated assembly system beneath the robot.
  • the position of the robot relative to the structure can be determined by calculating, for example, the number of structural units traversed.
  • Detecting distinct structural units in a model, such as a point cloud dataset can be achieved using a convolution neural network or other machine learning algorithm.
  • the convolution neural network or other machine learning algorithm is trained for detecting distinct structural units in a model.
  • the robot may include a simultaneous mapping and localisation system.
  • the simultaneous mapping and localisation system is configured to determine a map of the structure in the locality of the robot and the robot’s location in that map.
  • the simultaneous mapping and localisation system comprises at least one sensor for mapping the robots environment.
  • the sensor may be a LIDAR scanner.
  • An in-plane LIDAR scanner can be placed, for example, on top of the robot body. The in-plane LIDAR scanner scans in a circular motion in a plane parallel to the surface of the structure. Using this information, the robot simultaneously constructs a map of its environment and keeps track of its location within it.
  • the accuracy of the simultaneous mapping and localisation mechanism can be improved by inputting data from an accelerometer placed on the robot that can use inertial data to interpolate between 3D scans. Further accuracy improvements can be made by using the BIM model or previous 3D scans to detect features of the environment which have a known position, and then measure the distance of the robot from these known features. This reduces the mapping and localisation mechanism algorithm to a simple localisation mechanism which typically has accuracy on the same order as the accuracy of the LIDAR sensor.
  • the robot may include a light based positioning system, such as Ultra-Wide Band (UWB) or infrared laser systems (e.g. HTC VIVE’s Lighthouse solution).
  • UWB Ultra-Wide Band
  • HTC VIVE infrared laser systems
  • the light based positioning system uses a set of base-stations at known positions on or near the structure. These base- stations emit light in such a way that by sensing the variations in light intensity a light sensor can compute its 3D location. By placing sensors on the robot and ensuring line-of-sight between the robot and the base-stations the robot can track its position through space.
  • Figure 19 shows an exemplary flow diagram for the software the computes the robots location based on a range of sensory information.
  • the diagram is split up into two parts.
  • the part labelled absolute position shows how the global position is calculated using the LIDAR scan data and knowledge of the built environment given by the BIM model and on-site scan data (if available, hence the dashed lines).
  • the part labelled relative position shows how the position of the robot is updated when new scan data from the horizontal scanner that is positioned on top of the main chassis isn’t available and updates the position based on detected changes from various other sensors.
  • Absolute position is calculated by obtaining LIDAR information 19540 about the relative positions of parts of the surrounding environment. Feature detection is then used 19540, using such methods as convolutional neural networks trained to detect BIM objects in LIDAR data or, if as-built data is available 19610, using algorithms that align two different point cloud dataset scans of the same space. Using the known position of these objects and the scan data the robots position can then be computed and updatedl9560 19570 19580 .
  • sensor data is taken from the accelerometer 19620, the change in joint positions 19630 and if available vertical scan data 19640 of the brick structure, to compute the change in the robots positionl9650 19660.
  • Kalman filtering these different inputs are combined to produce a more accurate calculation than each sensor input would provide individually. For the case of the scan data we would estimate the number of bricks that the robot had traversed using algorithms trained to detect bricks in point cloud data.
  • FIG 43 illustrates an example setup where fiducial markers 43322, 43400, 43420, 43700 are used to improve localisation accuracy of the robot 43500 on the structure 43320 to allow it to accurately place bricks.
  • Each brick or discrete construction unit may have a marker 43322 applied or built into its structure, allowing its position and orientation to be quickly deduced by interpreting the marker 43322.
  • Similar markers 43322, 43400, 43420, 43700 may be applied elsewhere in the build environment - these may be 2d stickers or 3d formed objects or even light emitting/reflecting devices e.g. UWB (ultra- wide band) markers.
  • UWB ultra- wide band
  • markers 43400 fixed to rigid points on the ground e.g. the concrete foundation pad. Such markers may be used as calibration points for the rest of the build, marking out specific locations in space.
  • vision systems 43100 or cameras which may be LiDAR, depth sensing or standard vision cameras. Here they are shown mounted on a tripod but may also be mobile such as wheeled robots or flying drones. They also have a marker 34320 mechanically attached to the camera system so other cameras may see each other and therefore register their relative positions. These cameras are connected to a computer 43200, either with wires or wirelessly.
  • the robot 43500 assembling the brick structure 43320 is equipped with a marker, so its position can be determined by other robots and vision systems 43100.
  • the robot 43500 also has an on-board camera so it can register other markers 43322, 43400, 43420, 43700 on bricks and around the site. The visual data captured by any of the cameras may be communicated to other robots, cameras or computers around the site.
  • this setup allows the tripod-mounted cameras to carry out high resolution 3d scans or photographic images of the site. These scans or images are processed in the computer 43200, determining the absolute position of each marker 43322, 43400, 43420, 43700 on the site. This may be improved through multiple triangulations of different markers from different camera locations, using a Kalman filter for example. These positions of each marker 43322, 43400, 43420, 43700 are then broadcast wirelessly to the robot on the structure e.g. as a list.
  • the robot 43500 on the structure 43320 deals with a much lower load of computation: it needs only a lower-resolution camera able to work at short range; when it encounters a marker, it can refer to the list of all marker locations which it has received, and thereby determine its global position accurately without any further computation.
  • the robot may have an onboard computer as well as cameras, depth cameras or LiDAR to allow object recognition and SLAM. These may be used in conjunction with calibration points, markers or tags on the construction site, to allow more accurate positioning of the robot.
  • the robot may combine this global estimate of the robots position with relative measures, e.g. the observed distance to the previously laid brick, for accurate brick placement.
  • the robot may transmit or receive data about its environment to or from a central computer or other robots, to allow the state of the environment and build to be updated, monitored and managed.
  • the assembly system for assembling a structure out of a plurality of structural units may comprise a robot; a marker; and a marker reader, wherein upon reading the marker, a location and/or orientation of the marker or a location and/or orientation of the marker reader is determined.
  • the markers may be applied near or on any member within the assembly system.
  • the markers may be applied to any one or more location that a robot visits.
  • the markers may be applied to the robots also such that the robot scan be located within the system.
  • the markers may be applied to or near any one of the following: the robot, a structural unit, the marker reader, a connecting material trough, a connecting material store, a pallet, a structural unit location, an out of out of structure entry-exit system, a supply point, a platform, a building material production system, the structure, and/or any other locations the robot visits on or around the structure.
  • the marker may be on the robot such that the robot’s position can be determined by the marker reader.
  • the position of the robot may be sent to the robot additionally. Where multiple robots are used in the system, the position of each robot may be transmitted to each robot such that the robot is aware of all other robots in the system. This helps with collision avoidance as herein described.
  • the position of structural unit(s) may also be transmitted to the robot(s) such that the robot(s), with their current position, can find the nearest structural unit.
  • the system may comprise a further marker reader, and wherein at least one of the marker readers comprises a further marker such that the relative position of the marker readers is determined.
  • the system may further comprise a controller in communication with the marker reader and robot.
  • the controller may be considered part of an external monitoring system.
  • Figure 51 shows diagram/flowchart illustrates the process by which the robot 51000 localises itself in space using the fiducial markers with the assistance of an external monitoring system 51100.
  • the external monitoring system 51100 continually scans 51120 the environment to high-precision using, for example, LiDAR scanners and high-resolution cameras. This data is then processed and the position and orientation of each fiducial marker or brick is calculated to high-precision 51110. This information is sent out to all the robots, illustrated by the update arrow that passes from the external system to the robot.
  • the robots 51000 using for example their camera system, are able also to detect 51020 the fiducial markers on the bricks and measure 51030 their distance and orientation relative to each.
  • each brick/marker as calculated by the external system 51100 can then be used to accurately determine 51040 the position and orientation of the robot itself.
  • the more accurate external system 51100 ensures that the error in this calculation is only due to the error in the robots calculation of its own distance relative to the marker/brick, not the error in the position of the marker/brick itself.
  • the estimate of the robots position can be improved, by using Kalman filters for example, with covariance matrices estimated from the distance and orientation of the markers and the known errors for the given camera or detection system.
  • the robot comprises at least one structural unit positioning system which detects the position and orientation of a structural unit as the structural unit is placed on the structure by the robot.
  • a structural unit positioning system which detects the position and orientation of a structural unit as the structural unit is placed on the structure by the robot.
  • the robot may include a proximity structural unit positioning system.
  • a proximity structural unit positioning system comprises proximity sensors placed on the gripper which detect the relative distance between the gripper and the brick being placed. Using the position of the gripper, obtained, for example, from the position of the robot and the relative joint positions, and the orientation of the gripper, obtained from a three-axis gyroscope sensor placed on the gripper, the position and orientation of the brick can be computed.
  • the robot may include a stereoscopic structural unit positioning system.
  • a stereoscopic structural unit positioning system comprises a stereoscopic camera placed on the robot body looking down towards the gripper. Using the global position of the robot, the relative position of the camera and machine learning algorithms trained to measure the position and orientation of a brick from depth-map images, the position and orientation of the brick can be calculated. This has the added benefit of being able to monitor the position and orientation of bricks already placed as the robot manoeuvres over the structure.
  • the robot comprises at least one structural unit position correcting system for fine tuning the position of a structural unit, such as a brick, when the structural unit is being placed onto a connecting material bed.
  • the structural unit position correcting system comprises at least one structural unit position sensor, which checks the position of the structural unit, and at least one structural unit positioning device, which moves the structural unit. There is a feedback loop between the structural unit positioning device and the sensor to automatically affect the required adjustments to the structural unit’s position.
  • the structural unit positioning device may be the gripper.
  • the structural unit positioning device may be a tapping device, which moves the structural unit vertically and/or horizontally in each corner and/or edge by tapping and/or vibrating on the corresponding part of the structural unit.
  • the structural unit positioning device may comprise a rotating eccentric mass driven by a small motor, similar to a rotating pile driver or resonant actuator.
  • This motor assembly is mounted on a substructure of the robot which is free to move in one degree of freedom, such that the direction of the force from the structural unit positioning device is in a known direction.
  • the robot may be configured to change the positioning force, as required.
  • the positioning force may be changed, for example, by changing the speed of the motor, and/or changing the resonant frequency of the moving element etc.
  • the robot control software may calculate the required changes to the positioning force from input sensor data and carry out the required taps. This is repeated until the brick is in the desired position, to within a required tolerance.
  • each structural unit positioning device may vibrate individually and the response of the structural unit, i.e. change in position of the brick, be detected. This calibrates the impact on the position of the brick induced by a given force and location of force application.
  • a set of locations and forces can be computed to achieve a desired change in the bricks position. This can be achieved by using, for example, a neural network trained to predict the change in a bricks position given calibration data and a known force and direction of application.
  • the resulting required actions are enacted by each structural unit positioning device and the resulting change in the bricks position is measured using the sensing devices. This cycle repeats until a threshold level of accuracy has been achieved.
  • Figure 20 is a diagram illustrating an exemplary high level control flow for the robot when placing a brick.
  • the brick is placed initially by the movement of the main chassis of the robot to lower it into place and release the gripper 20670. After the coarse grain placement the robot detects the position of the brick using sensors on the gripper 20680. This gives the x,y,z, yaw, pitch and roll of the brick. This is compared to the position and orientation required by the BIM design 20690. If it is in place to the sufficient degree of accuracy the action is complete. If not the robot calculates the appropriate action tapping action required by the grippers tapping actuators 20700. This action is then performed and the bricks location is again measured and the process repeats 20710.
  • Figure 53 shows a flowchart that shows the method 53100 by which a brick is placed in the case where oscillations are employed to help reduce the viscosity of the mortar.
  • the first input 53200 is the position and orientation of the robot and the target position and orientation of the brick. From this a placement trajectory is calculated 53110, which in the case of laying a brick flat on top of a wall is typically a downwards vertical motion, though it also may contain some horizontal component. The trajectory is calculated 53110 such that it avoids collision with any objects on the way in.
  • the brick is then positioned 53120 at the start of this trajectory and then the orientation of the brick is set such that it is the same as the target. This is the orientation about which the brick will be oscillated .
  • the oscillation frequency and amplitude are obtained 53300, these may be set at the start of the build process and be based on factors such as the consistency of the mortar and the size of the bricks.
  • the axis of the oscillation will depend on the way in which the brick is gripped. Typically the brick will be rotated along the yaw axis for the case of vertical placement.
  • Mortar used in brickwork is a shear-thinning non-Newtonian fluid. Therefore, when the brick is being placed, a control program may be used to oscillate the brick in any of the above degrees of freedom e.g. yaw to facilitate shearing in the mortar, resulting in thinning of the mortar allowing the brick to be placed onto a mortar bed with a relatively low force.
  • the brick may be held in such a way that the centre-of-mass of the brick aligns with the axis of oscillation so that minimal vibration is produced from the action. Once in place the force required to move the brick is increased due to the lack of sheer and the robots are able to move on the structure without disturbing it.
  • the robot may be configured to place a structural unit onto a bed of shear-thinning connecting material.
  • the robot may be is configured to move the structural unit into a starting position; agitate the bed of connecting material such that the bed of connecting material decreases in viscosity; move the structural unit into a final position; and cease agitation.
  • the starting position may be close to final position of the structural unit.
  • the starting position may be above the final position.
  • the robot may move the structural unit above the final position.
  • the robot may move the structural unit with an effector.
  • the starting position may be close to a final position of the structural unit.
  • the starting position may be a position above the final position,
  • the agitation caused by the robot may be conducted by oscillating the structural unit with the effector.
  • the oscillation of the structural unit is along a vertical axis.
  • the oscillating motion of the structural unit may move the structural unit towards and away from the final position of the structural unit.
  • the structural unit may be oscillated along the same direction as a direction of travel of the effector.
  • the effector is moveably coupled to the body of the robot, wherein during oscillation of the structural unit the effector and structural unit move in the same direction relative to the robot body
  • the effector may be configured to move relative to the robot body along an oscillation axis.
  • the oscillation axis may extend towards and away from the robot body.
  • the structural unit may oscillate along that axis.
  • the robot may also be configured to do any one or of: receiving structural unit orientation; calculating placement trajectory; and receiving oscillation axis, oscillation frequency and/or oscillation amplitude.
  • the effector may be configured to move with a single degree of freedom.
  • the movement may be along a vertical axis.
  • the oscillation of the structural unit may be in that same degree of freedom. Having only one degree of freedom allows for simpler effect construction and control.
  • the robot is configured to position itself appropriately such that the effector is directly above a structural unit (or ramp) about to be gripped.
  • the effector may have a plurality of degrees of freedom, and preferably the effector is free to move vertically and rotate about the vertical axis.
  • the effector may be configured to oscillate the structural unit about the vertical axis.
  • the effector may be configured to oscillate the structural unit rotationally about the vertical axis in addition to oscillating the structural unit in the vertical axis.
  • the effector may be configured to move relative to the robot body along an oscillation axis, and preferably the oscillation axis extends towards and away from the robot body.
  • the structural unit may oscillate in rotation about that oscillation axis.
  • the effector may be configured to oscillate the structural unit along or rotationally about an oscillation axis.
  • the effector is configured to oscillate the structural unit along and rotationally about the oscillation axis.
  • the effector is configured to oscillate the structural unit along and rotationally about the oscillation axis at the same time
  • the robot may comprise an agitating means to agitate the shear-thinning connecting material.
  • the agitating means may be a separate agitating tool.
  • Figure 31 contains a diagram showing a plan view of an exemplary construction site during the build process.
  • the dashed lines 31320 indicate the brick structure being built. Arrows indicate the direction of travel of the robots. Squares indicate supporting equipment and pathways.
  • Next to the brick structure are the window bypasses 31900, 31901 that indicate that when the brick structure reaches a height at which the robot cannot continually travel along the brick wall the robot can enter the bypass and leave, following the direction of the robot flow, to get around this occlusion.
  • the up-staircase 31820 and down- staircase 31821 represent the staircases as shown in the hardware diagrams, these allow access to all the levels of the brick structure and are accessible from the main supply path 31240. Also connected to the main supply path and accessible is the connecting material supply point 31220, the material supply point i.e. bricks 31220, the wall tie supply point 31221 and the charging station 31960.
  • Figure 58 illustrates a further 2D schematic of a further example site layout similar to that as described with reference to Figure 31.
  • the squares illustrate different structures and supply points. Arrows indicate the direction of travel of the robots.
  • the dotted lines represent the structure being built.
  • the layout is very similar to that of the diagram as shown in Figure 55 but with the wall-tie supply in a different position and the up and down staircase/ramps in separate locations.
  • the window passes represent pathways by which the robot may leave the main structure and return further along in order to get around gaps in the build due to windows and doorways.
  • Assembly control involves avoiding collisions, interference and blockages that can slow down the build process as well as being flexible enough to adapt to changing numbers of robots and external input from humans.
  • the assembly control program sets virtual valves to control the“flow” direction of robots.
  • Valves are regions of space for which certain directions of movement are prohibited. Valves may be set centrally by the assembly control program. Alternatively, valves may be set by the robots themselves as they traverse the build environment. In this case, robots may treat the valve like a pheromone trail, such that the first robot to approach the valve sets its direction (and the subsequent direction of flow). Valves may be set as a global constraint in that all robots obey the constraints. Alternately, valves may be set as a local constraint in that only certain robots obey the constraints. Valves are useful for circular structures where a continuous“flow” of robots between the build structure and the supply points can be established by setting up effective“one-way streets”.
  • the assembly control program sets virtual checkpoints to avoid blockages, robot collisions and for general safety procedures.
  • checkpoints consist of regions of space. These regions may be defined centrally by the assembly control program.
  • Checkpoints may be set as a global constraint in that all robots obey the constraints of the checkpoint. Alternately, checkpoints may be set as a local constraint in that only certain robots obey the constraints of the checkpoint.
  • the robot may perform safety checks. If the checks fail, the robot may be configured to wait and repeat the checks after a fixed time delay. Alternatively, if the checks fail the robot may be configured to perform some other action.
  • the robot may, for example, continue on its way. This might be used to prevent two robots entering a given area of the build, for example. In this case the check might be, is there a robot in a given region of space. If yes, then the robot must wait. If no, the robot may continue on its way. This can be used to prevent collisions between robots and blockages.
  • Figure 21 is a diagram showing example situations where valves 21720-1 and checkpoints 21730-1 are used to control the flow of robots. These elements combined with built- in collision avoidance are sufficient to ensure the robots do not crash or importantly create blockages that slow the build process.
  • the flow of the robots is indicated by the arrows and the valves and checkpoints are indicated by the squares.
  • The“access to supplies” square 21740 can be thought of as an access staircase that allows the robots access to material supplies and all heights of the brick structure.
  • the upper arrow that connects to the access staircase to the brick structure is the entry point, the lower arrow is the exit point, as indicated by the direction of the arrows.
  • the brick structure 21320 is indicated by the dashed lines.
  • the upper diagram shows a brick structure with a circular topology.
  • This circular topology allows for the definition of robot flow which is enforced using the valve at the entry point where the robots, upon entering from the supply staircase, are forced to move in an upwards direction.
  • These valves also control the path finding algorithms of the robots. Hence if the robot is finding a path back to the supply staircase, its only viable route is to walk all the way around the brick structure to the exit point. This ensures that no robot turns back at some other part of the brick structure where there are no valves.
  • This flow setup enables multiple robots to walk around the structure without blocking each other's way. The only region where this unidirectional flow is not possible is in the region between the entry and exit points.
  • the lower diagram shows the flow control for a single brick wall structure.
  • This structure has a linear topology so no circular current or flow can be established. Robots must walk back and forth along this structure and potentially block each other's way. To avoid this, a checkpoint is located at the entry point to the brick structure from the supply staircase. Robots wait at this checkpoint if there is another robot on the brick structure.
  • the automated assembly system may include at least one bypass system that, when placed next to the openings in the brick wall, enable a continuous path from one side of the opening to the other.
  • the bypasses comprise a support structure e.g. columns that uphold level surfaces that form a path out away from the plane of the wall and round to the other side of the opening.
  • these level surfaces occur every 3 courses, ensuring that a path is accessible at all intermediate heights of the brick structure using an up, down or level step by the robot.
  • the level surfaces alternate in the extent of their protrusion away from the plane of the brick structure.
  • the total head room is twice the height of 3 courses.
  • Figure 30 shows an exemplary perspective view of a design for a bypass structure, here shown enabling the robot to bypass a window gap in the brick wall structure 30320 shown behind.
  • the bypass consists of a main supporting frame 30910, shown as the thick cylindrical poles or supports. This frame upholds level surfaces traversable by the robot that enables continuous access from one side of the window to the other.
  • the robot is illustrated manoeuvring on one of the level surfaces 30920 at the same height as the current brick course.
  • the level surfaces occur every three brick courses, ensuring that a path is accessible at all intermediate heights of the brick structure using an up, down or level step by the robot. Every alternate level surface illustrated in the diagram provides a path that protrudes further from the brick wall, going around the level surfaces closer to the brick wall.
  • the robot illustrated is shown on such a path. This ensures enough head clearance for the robot to be able to move along the bypass. Thus, the total head room is twice the height of 3 courses.
  • Figure 29 shows a side on view of an exemplary bypass structure.
  • the support frame 29910 On the far right we see extending vertically the support frame 29910, holding up five attached structures. These attached structures are the level surfaces eg 29920 that provide pathways for the robot to traverse from one side of the gap in the brick wall (in this case a window) to the other.
  • Each of the five attachments to the supporting frame holds up two such pathways, one at the same height as the attachment point 29920 (such as the one the robot is illustrated standing on in the middle) and another three brick courses higher 29930 giving a total of ten level-surface pathways.
  • level-surface pathways occur every three brick courses, ensuring that a path is accessible at all intermediate heights of the brick structure using an up, down or level step by the robot.
  • the alternating design of the level surfaces, such that every odd pathway extends around and out away from the brick surface gives a head clearance twice the height of three brick courses, sufficient for the robot.
  • Figure 28 shows a perspective view of an exemplary bypass structure on its own. It shows the supporting frame 28910 at the back of the image, with the attached level-surface 28920-4 28930-4 pathways for the robot in the foreground. See descriptions of Figure 9 and Figure 30 for more information.
  • the automated assembly system may include at least one staircase system.
  • a staircase system can be used to enable the robots to climb up and down between different levels of the structure.
  • a staircase system comprises two spiral staircases that are supported by vertical support columns. In this way, one robot may climb from the bottom of the structure to the top of the structure at the same time as a second robot climbs from the top of the structure to the bottom of the structure.
  • Each spiral staircase provides structure access points at which the robot may access the structure. If a robot is only able to climb up or down one course at a time, the access points may be provided at heights corresponding to every three courses of the structure to be built. This ensures the robot may access the structure at all intermediate stages of the build.
  • the robot can trivially access course 0 by taking a level step from the ground level access point.
  • the robot can access course 1 of the brick structure by taking a step up from the ground level access point.
  • Course 2 can be accessed by the robot by taking a step from the ground level access point on to course 1 and then placing a brick on top of course 1, creating course 2.
  • the robot can then continue to access course 2 of the brick structure from the access point at course 3 by taking a step down.
  • the spiral staircase design gives a total headroom for the robot of twice the height of three brick courses.
  • the staircase may also comprise a pathway that extends away from the structure to enable access to a supply point, such as a brick pallet of cut or full size bricks.
  • the staircase system may be powered such that the robots can charge the robot batteries as the robots use the staircase system.
  • the staircase provides access every three courses because the robot, from any given level can access three levels. That is, the same level, the level one below and the level one above.
  • the robot can also lay bricks on any of these levels. If we take the case where the robot is accessing the brick structure from a staircase at course 3, the robot can step up onto the structure and thus be walking on course 4. Once on this level the robot can lay bricks, thus laying the bricks associated with course 5.
  • Course 5 is accessible via a step down from the staircase access point at course 6, three courses above the current access level. Thus if the robot lays the bricks in front of this higher access point (at the height of course 6) then it can start accessing the brick structure at this level.
  • Figure 25 shows an exemplary staircase 25820 that enables the robot 25000 to access different heights of the brick structure.
  • the staircase consists of a supporting frame that upholds level surfaces 25840 forming the stepping and walking points for the robot. These level surfaces form two spiral staircases, one on the left and one on the right, enabling two robots to walk up and down simultaneously without having to pass each other. The difference in height of the level surfaces that form the steps is equivalent to the height of a brick.
  • the supporting frame consists of outer vertical support structure 25850 25851 and an inner frame 25860 that holds up the level surfaces forming the staircases.
  • the outer vertical support structure consists of two vertical poles 25870 25871 on either side held together with five cross attachments 25880-4.
  • the inner frame is detachable from the outer supporting frame enabling the height of the staircase to be changed depending on the requirements.
  • the inner frame is hinged at the points where the parts that uphold the level surfaces meet the parts that connect to the outer supporting frame. These are illustrated by circular protrusions in the diagram. This enables the inner staircase frame to be folded-up and packed efficiently for distribution and transport.
  • the diagram shows the robot placed upon the ground level surface of the staircase that protrudes away from the brick wall (not shown). This level-surface provides access to, for example, brick supplies and charging stations etc. Access to the wall is provided every three brick courses to enable the robot to step on to the wall at all intermediate heights during the build process.
  • Figure 27 illustrates the design of the staircase 27820 shown in Figure 25 positioned in front of a brick wall 27320.
  • a robot is shown positioned on the level surface that provides access to the brick wall at its current height with a step-down.
  • the outer supporting frame 27850 27851 can be seen on either side of the staircase.
  • the inner-frame 27860 supporting the level surfaces 27850 that the robot manoeuvres on is shown, with the circular hinges visible at each level of the staircase.
  • Figure 26 shows a side-on view of the staircase design. It includes a brick wall 26320 structure on the far right, accessible via the staircase 26850, and a brick supply pallet on the far left 26330.
  • the robot 26000 is positioned on the ground floor pathway 26240 of the staircase that provides access to the brick pallet on the far left.
  • the access points from the staircase to the brick structure occur every three brick courses and the alignment of the steps with the brick structure.
  • each stepped element may be a modular component.
  • the robot would be able to climb the staircase thus assembled and add to the top of the staircase. This process could also be performed in reverse at the end of the build process.
  • the automated assembly system may include at least one lift system.
  • An example lift system uses compartments or platforms mounted on a vertical rail, controlled with a motor and balanced by a counterweight.
  • the lift system includes a control program which communicates with the robots, such that robots wait in designated‘lobby’ areas. This prevents robots from blocking access to the lift, or to other areas in the automated assembly system. Further, the lift and/or designated lobby areas may provide charging facilities for the robots.
  • Figure 22 shows a perspective view of an exemplary robot vertical transportation device or lift 22750.
  • This consists of a primary vertical structure, a linear rail mounted vertically 22760 on which moves a platform or lift car 22770. This is driven by a motor, and balanced with a counterweight 22780.
  • the platforms are arranged vertically such that the step height between each platform and each brick level of the target structure is within the robot’s capabilities, and also that there is sufficient clearance height between stationary platforms for the robot to stand.
  • the platforms are arranged each third course of bricks, assuming the robot can step up one brick or down one brick height.
  • the platforms are also alternating each side to allow the clearance height of approximately six bricks.
  • the robot may interact with the lift’s control software using a variety of methods such as pressure, proximity, visual sensors etc, or may communicate directly via wireless communication.
  • Figure 23 shows a side elevation view of an example robot vertical transportation device 23760. It shows an example built structure 23320 composed of bricks, with the stationary platforms 23790-3 attached to the lift primary structure arranged so as to interface with the built structure in intervals to allow the robot to move between the structure and the platforms. It shows the moving lift platform mounted to the primary vertical structure, supported by a cable element. This cable is attached to a counterweight 23780, via a pulley which is driven by a motor 23800.
  • Figure 24 shows an exemplary sequence of perspective views of an example robot vertical transportation device. It shows the purpose of the stationary platforms being used as waiting areas by different robots. This allows the lift to be used effectively by multiple robots.
  • the first diagram shows one robot 24000 entering the lift at the lower level, aiming to deliver its brick to the built structure.
  • the second diagram shows another robot 24001 entering onto one of the stationary platforms on its respective level. It has been informed by communication with the lift or general robot network that the lift is currently at the bottom, so it must wait for the robot currently in the lift to exit before it enters.
  • the third diagram shows the lift having been raised to the current working level. Because the returning robot 24000 is waiting on the stationary platform, the lift exit is clear for the outcoming robot 24001 to leave the lift and carry its brick to the built structure.
  • the fourth diagram shows the returning robot having side-stepped onto the lift platform in order to be taken down to the lower level.
  • Figure 35 illustrates a ramp structure 35300 that enables wheeled access to intermediate levels of a straight brick or block structure. It comprises flat platforms held up by supports, in this example five such platforms on the right of the structure 35300 and four on the left. These platforms are linked by two ramped slopes enabling wheeled access between each platform. Each platform enables wheeled access to the brick or block structure at the height of the platform. The heights of the platforms are dictated by the size of the brick or block elements used for construction as well as the height of the robot which determines the maximum headroom required for the ramped pathways connecting the different platforms. Thus, depending on the robot and brick or block material used this structure 35300 may provide access to every nth level.
  • Two ramped structures are used to connect each platform to enable simultaneous ascent and descent of the structure 35300 by multiple robots 35100 35200.
  • the two ramped pathways may be mirrored, such that there is a distinct entrance and exit to the structure 35300.
  • the pathways for the robots 35100 35200 are marked on the structure 35300, illustrated by two parallel black lines on the ramps and platforms that form a continuous path from the top to the bottom of the structure 35300.
  • This pathway marker may have a functional purpose, such as indicating which ramp is to be used for ascent/descent through, for example, lights of passive arrow detailing, or to provide power to the robots 35100 35200 to charge their respective batteries.
  • the ramp structure can be considered an out of structure system or an off structure system.
  • the ramp structure may allow the robot the robot to move up and down multiple levels at once, for example from the material supply on the ground.
  • the connected ramps may have built in electrical contact points, strips, or induction coils to allow the robots to charge their batteries whilst on the ramps.
  • the ramps may be arranged in a spiral, or in parallel lines to the wall of bricks. Horizontal landings in between the sloping sections allow robots to access the corresponding layers of the structure. Two ramps may be arranged in close proximity, with interlinking landings to allow access to the wall. This arrangement allows one ramp to be used for ascending and the other descending, so the robots do not crash into each other.
  • the ramps may be standalone structures, or attached to standard scaffolding poles using clamp connectors.
  • the ramps may collapse using hinged and/or telescopic structure(s), or be composed of separate parts to allow flat packing. These separate parts may also be configured to be assembled by a similar robot to the main structure.
  • the ramps may have visual markings such as lines or visual tags to allow easy identification, calibration and navigation by the robots. These ramps may also be fitted with wheels, tracks or legs to allow the ramps to autonomously reposition themselves relative to the structure.
  • An assembly system for assembling a structure out of a plurality of structural units comprises a module by which a robot may enter the structure or a module by which a robot may exit the structure; at least one robot configured to enter or exit the structure via the out of structure entry-exit system.
  • the module by which a robot may enter the structure or a module by which a robot may exit the structure may comprise a transport means for repositioning the module relative to the structure.
  • the transport means may be an automated transport means such that the module repositions itself.
  • the module by which a robot may enter the structure or a module by which a robot may exit the structure may comprise multiple entry-exit points at different heights.
  • the module by which a robot may enter the structure or a module by which a robot may exit the structure may comprise a charging feature, and preferably a charging station or rail, and preferably the charging feature is configured to charge a robot using the structure.
  • the module by which a robot may enter the structure or a module by which a robot may exit the structure may comprise a ramped path between multiple levels of the structure, and preferably the ramped path comprises a plurality of inclined surfaces.
  • the module by which a robot may enter the structure or a module by which a robot may exit the structure may comprise a staircase comprising a plurality of steps between a plurality of access levels, wherein the access levels are preferably at heights corresponding to every three steps.
  • An assembly system for assembling a structure out of a plurality of structural units comprises a first and second module by which a robot may enter the structure or a module by which a robot may exit the structure as herein described; and at least two robots configured to access or exit the structure via the modules, wherein the at least two robots exit via the first module and exit via the module.
  • Figures 36 and 37 illustrate an example design of an active ramp 36100 37100 from two different angles.
  • the active ramps 36100 37100 comprise a sloped surface of arbitrary angle and length attached to a wheeled or, as illustrated here, a tracked robotic platform 37120 38120.
  • the robotic platform 37120 38120 is capable of changing the position of the ramp 37100 38100 by controlling the tracks/wheels using, for example, a differential drive system.
  • the ramp 37100 38100 is shown here attached to the robotic platform 37120 38120 above the wheeled base near the top of the ramp 36100 37100 and horizontally along from the robotic platform 37120 38120 near the base of the ramp 36100 37100.
  • These attachments may comprise linear joints, capable of being controlled by the robotic platform 37120 38120, allowing the gradient of the ramp 36100 37100 to be altered by raising the height of the top of the ramp 36100 37100 and/or drawing the base of the ramp 36100 37100 nearer to the tracks/wheels.
  • a passive wheel/wheels such as a trolley wheel, that enables the base of the ramp to move freely.
  • the ramped surface is designed to enable wheeled access to higher or lower levels (typically one level higher/lower) of a brick or block structure.
  • Active ramps 36100 37100 will be capable of driving over other active ramps 36100 37100 enabling the automatic transformation of staircase like structures into smooth ramped structures, rendering them more accessible to wheeled or tracked robots. They may be controlled wirelessly by individual robots, or by a central controller, or may be fully autonomous within a structure. E.g. they may be instructed to navigate around a brick structure using simple rules such as sensing the edge of the wall using light or distance sensors, with the aim of finding any remaining‘stepped’ areas. If a‘step’ is found, the ramp 36100 37100 would position itself to render the‘step’ traversable.
  • Figure 38 illustrates an example use case of two active ramps 36100 37100 on a brick/block structure. It shows two active ramps 36100 37100 enabling wheeled access from the lowest level of a brick structure to a central brick on the level above.
  • Figures 39 and 40 illustrate a design of a passive ramp 39100 40100.
  • Figure 39 shows the passive ramp 39100 in place on a brick structure 39320
  • Figure 40 shows the passive ramp 40100 raised above the brick structure 40320.
  • the passive ramp 39100 40100 comprise a sloped surface of fixed angle and length. In this case the height and length are the height and length of one standard masonry brick.
  • In the middle of the ramp 39100 40100, at both the top and bottom, are two attachments which are designed to enable a passing robot to change the position of the ramp 39100 40100. This may comprise, for example, hooks or magnets, to which the robot may engage temporarily in order to manipulate the ramp 39100 40100.
  • the ramp 39100 40100 may also be picked up and moved using a robot end effector, e.g.
  • the upside-down F- shaped attachments at the front of the ramp 39100 40100 are designed to engage with the gripper.
  • the central square in the middle of the ramp 39100 40100 indicates a fiducial marker which may be used by the robot to obtain the position and orientation of the ramp 39100 40100. This can be used to help localise the robot if the position of the ramp 39100 40100 is known, or to help move the ramp to a desired location.
  • Below the top of the ramp 39100 40100 is a gap. This is to prevent the ramp 39100 40100 from having contact with wet mortar when a brick is placed next to it.
  • At each side of the ramp 39100 40100 are two overhanging parts which help the ramp 39100 40100 to passively clamp to the brick structure 39320 40320 and prevent the ramp 39100 40100 from falling off the wall or misaligning with the brick structure 39320 40320.
  • Figure 41 shows two passive ramps 41100 in place on a brick structure 41320 enabling access to a higher level which comprise a single central brick 41200.
  • the gaps below the top of the ramp 41100 can be seen here to help prevent contact between the mortar bed and the ramp 41100.
  • Figure 46 illustrates an example robot 46000 about to place a brick coated with mortar into position on a wall 46329.
  • This robot is designed to operate in an environment in which active or passive ramps are used, as it does not have the capacity to step up or down one level of bricks/blocks.
  • the design comprise a main chassis atop two“feet”, each foot comprising a rotational joint acting about the central vertical axis and two tracks. Each foot is capable or orienting independently, the angle of which is controllable using both the rotational joint and differential drive of the two tracks.
  • On top of the main chassis is a passive structure that is capable of holding a brick in place.
  • the T-shape structure at the back comprises two linear joints and forms the main arm of the robot, enabling movement of the gripper up and down and forwards and backwards.
  • the gripper is illustrated at the far left end of the main arm and comprises three rotation joints controlling the yaw, pitch and roll of the linear joint that forms the gripper.
  • This gripper is attached to the horizontal beam, which is placed in front of the vertical beam to enable the gripper to access both the front and the back of the robot.
  • the vertical joint extends to the very base of the chassis and there is a gap between the chassis and the vertical beam for the horizontal beam to pass into (this is illustrated in Figure 48.
  • This may be used to store bricks during transport (to enable higher speeds or to carry multiple bricks at once) or to store other devices used in the build such as end effectors and passive ramps.
  • At the front is an opening from which the mortar is extruded.
  • the main mortar store is contained within the chassis and may be extruded using a plunger system or archimedes screw, for example.
  • the mortar is applied to the brick by moving brick in front of the mortar extrusion hole using the robot arm and gripper as the mortar is extruded.
  • One side of the robot may be flush with the brick surface, in this case the near side, to enable passage past, for example, lintels.
  • the other side may be designed to extend no more than 50mm from the surface of the wall to enable passage past cavity walls in either orientation, though this requirement isn’t essential for basic functionality.
  • a socket which is a charging port for the robot to enable it to drive into a self-charging dock.
  • the brick is currently held in position above its target position on the wall.
  • the arm will be lowered down below the level of the chassis as illustrated in Figure 48.
  • the yaw rotational joint of the gripper may be oscillated to apply shear stress to the mortar in order to reduce its viscosity and reduce the required force to place the brick in position.
  • the space in which the brick is being placed is between the already laid bricks and a passive or active ramp.
  • the robot may have an electro-magnet at the rear near the charging port such that once the brick is laid the robot may drive forwards, down the ramp and once the rear is near the end of the ramp it may turn on the electro-magnet, attaching to the magnet in the passive ramp, and move the ramp forward so that there is space for a new brick to be laid.
  • Figure 47 illustrates the same robot 47000 as in Figure 46 above from a different angle.
  • Figure 48 illustrates the placement action of the robot 48000 described above.
  • the horizontal beam of the robot arm is lowered to its fullest extent, passing into the gap between the vertical beam and the chassis, to enable bricks to be laid on the layer below that which the robot is positioned.
  • the robot can also lay bricks on the same level.
  • Figure 49 shows the steps by which the robot from Figures 46-48 places a brick in the passive ramp scenario.
  • the steps, going from left to right and top to bottom are as follows.
  • step 49001 the robot drives up the ramp to reach the top layer of bricks. This is the layer that is to be added to.
  • the robot is carrying a brick in its gripper and its mortar store is full or contains enough for one brick.
  • step 49002 the robot drives up to the brick just in front of the space in which the next brick is to be laid.
  • step 49003 the robot moves the brick in front of the mortar extrusion hole and extrudes the mortar such that the mortar is spread directly onto the surfaces that are to be bound to the wall, in this case the lower and right hand side surfaces of the brick.
  • step 49004 the brick is then placed in position at the start of the trajectory along which the brick will be placed. In this case this is directly above the target position of the brick, in the correct orientation.
  • step 49005 the brick is lowered into position along the trajectory that the brick is to be placed, in this case the trajectory comprises a vertical motion downwards.
  • the orientation of the brick may oscillate in order to apply sheer force to the mortar bed, thus decreasing the viscosity of the mortar and reducing the force required to place the brick.
  • the robot releases its grip on the brick.
  • step 49006 once the gripper is released the robot raises the gripper to a sufficient height so as not to interfere with the previously laid brick.
  • step 49007 if the position of the passive ramp in front of the robot is not sufficiently close to the brick that has just been laid, the robot may extend the gripper above the position of the ramp, in the correct orientation, in preparation for picking up and moving the passive ramp nearer to the brick to allow for a smooth exit from the upper layer.
  • step 49008 the robot lowers the arm and engages the gripper around the passive ramp such that the ramp is now held firmly in the gripper.
  • step 49009 the robot then moves the arm backwards brining the ramp as close as possible to the freshly laid brick, enabling a smooth exit from the upper layer. This action may occur in one smooth horizontal movement or it may involve an intermediate raising and lowering of the gripper.
  • step 49010 the robot then disengages the gripper from the passive ramp and returns the gripper to its central resting position along the middle of the horizontal beam.
  • the resting position may be as low as possible above the body to keep the centre of mass of the robot as low as possible.
  • step 49011 the robot drives onto the passive ramp.
  • step 49012 the robot drives off the passive ramp onto the lower layer just in front of the passive ramp.
  • step 49013 the robot lowers the gripper and extends it over the passive ramp, engages the gripper to clasp the ramp.
  • step 49014 the robot then drives forward approximately the length of one brick, leaving a space for the next approaching robot to place the next brick.
  • the robot releases its grip on the ramp and returns the gripper to the resting position.
  • the robot may be configured to apply connecting material to a structural unit to be placed.
  • the method used to apply connecting material may be that as described above with reference to Figure 49 and steps 49003 and 49004.
  • the robot’s effector may be configured move a structural unit about the nozzle such that connecting material is applied to the structural unit without movement of the nozzle.
  • Figure 50 illustrates the steps by which a wheeled stepping robot may place a brick without the need for ramps.
  • This robot has two tracked feet identical to the other wheeled robots, but each foot is attached to a linear joint that allows each foot to be raised independently. It may also contain an inner counterweight, such as a battery that is able to move to help the robot balance on a single leg. From top left to bottom right the steps are as follows.
  • step 50001 the robot is positioned on top of the brick in front of the current build face where the next brick is to be placed.
  • the robot is carrying a brick in its gripper above its feet.
  • the robot has driven forward on its back foot such that the front foot is hanging in the air.
  • the arm of the robot has been extended to act as a counterweight so that the centre of mass of the robot is above the rear foot. Any internal counterweight may also have been adjusted to enforce this condition for the robot to balance.
  • This internal counterweight is illustrated as the dotted square in the main chassis of the robot in this figure.
  • step 50003 the front leg is lowered onto the level below and the counterweights, both the robot arm carrying the brick and the internal weight, are adjusted such the centre of mass is over the centre of the robot again.
  • the robot arm and the internal counterweight are adjusted such that the centre of mass is over the front foot of the robot and the robot drives forward such that there is space for the rear foot to be lowered.
  • step 50005 the rear foot is lowered and the robot arm carrying the brick and the internal counterweight are centred once more.
  • step 50006 the robot drives forward sufficiently far to allow a space for the mortar canister to be extended.
  • step 50007 the mortar canister is extended such that the extrusion hole is positioned at the base of brick to which the new brick is to joined.
  • step 50008 the mortar canister is retracted as the mortar is extruded, spreading mortar along the surface of the brick to which the new bed is to be joined.
  • step 50009 the robot drives forward slightly and lowers the mortar canister once more such that the extrusion hole is positioned at the start of the mortar bed.
  • step 50010 the robot drives forward as the mortar is extruded from the canister creating a bed of mortar upon which the brick is to be placed.
  • step 50011 the mortar canister is retracted.
  • step 50012 the robot drives as close to the mortar bed as is required for the robot arm to be able to reach the position the brick is to be placed in.
  • step 50013 the robot arm and gripper are extended such that the brick is positioned above its target position.
  • step 50014 the brick is lowered into place by lowering the body of the robot down the leg joints. As the brick is placed the brick may be oscillated around a vertical axis.
  • step 50015 once the brick is in its target position the gripper is released and the robot body is raised up on the leg joints.
  • the ramp members may allow the robot to move up or down one or multiple levels without any additional climbing. This is useful as it can allow the robot to be a lot simpler e.g. just a single track system or multiple track system but with no independent height control for each trackset.
  • the ramps may be of the same height as one brick or more bricks, although may be adjustable in height to allow for finer calibration.
  • the ramps may be made of a lightweight material to allow easy repositioning by the robot.
  • the ramps may have gripping points to be easily picked up or moved by the robot with minimal effort.
  • the ramps may have other devices such as a magnetic contact to allow the robot to move the ramp using an electromagnetic or similar device.
  • the ramps may have a roughed or sticky surface on top and bottom sides to generate friction between the ramp and the bricks below and the ramps and the robot while it goes up or down the ramp.
  • the robot can move the ramps around to ensure that the next brick location is always accessible to the robot. In one example, this would involve the robot accessing the next brick’s level by a ramp up, driving past its location and down a ramp, moving the second ramp along by one brick’s length, driving back up the ramp, placing the brick in the space, and driving back down the ramp to get the next brick.
  • the ramps and bricks can be viewed as a combined system to allow the required traversability of the structure.
  • the ramp itself may be another robot, able to traverse the structure using a set of tracks, for example. This allows the ramp to automatically position itself in the most convenient location to assist the robot to place the next brick.
  • the standard structural unit may be in a wedge shape, such that two wedge bricks on top of each other equals the same volume as a cuboid- shaped brick.
  • the ramp member allows a robot to traverse a structural unit without the need for stepping.
  • the ramp member may be for placement on a structure comprising a plurality of structural units.
  • the ramp member may allow a robot to traverse from one layer of structural units to another. Thereby robots without height adjustable feet/legs are required and robots with only a track set can be used.
  • the ramp can still be used with robots that comprise height adjustable legs also.
  • the ramp member comprises an inclined plane configured to allow a robot to traverse the ramp member.
  • the height of the ramp member may be approximately an integer multiple or integer factor of the height of one of the structural unit.
  • the height of the ramp member can be approximately the same as the height of one of the structural unit.
  • the robot can traverse from one layer of structural units to another layer of structural units without the need for any additional stepping motion. If the heights are approximately the same, then the robot can traverse up or down a single layer of structural unis.
  • the ramp member may have the same or less width and/or length of the structural unit.
  • the ramp member may have gripping points configured to allow a robot to grip the ramp member.
  • the gripping points may be gripping attachments, such as gripping protrusions, such as upside-down L-shaped attachments.
  • the ramp member is configured to be gripped by the robots effector.
  • the ramp member may be sized similar to that of a structural member such that the same effector can be used to grasp both a ramp member and a structural unit.
  • the ramp member may be configured to move or be moved about a structure being assembled.
  • the ramp member may be moved by the robot picking the ramp member up, the robot moving about the structure being assemble, and placing the ramp in a new location.
  • the ramp member can move itself about the structure being assembled.
  • the ramp member comprises a traversing means.
  • the traversing means can be a track set similar to that of the robot.
  • An assembly system for assembling a structure out of a plurality of structural units may comprise a ramp member as herein described and at least one robot configured to traverse the ramp member in order to traverse from one layer of structural units to another.
  • the robot of the assembly system may comprise an effector configured to releasably couple to the ramp member.
  • the same effector is further configured to releasably couple to a structural unit.
  • the robot comprises a separate ramp effector to grasp the ramp.
  • the assembly system is configured such that the robot is configured move the ramp member about the structure such that the robot can access the next structural unit location.
  • the ramp member may be movable such that if it is in the way of where a structural unit is to be placed then the ramp moves or is moved out of the way temporarily.
  • the assembly system comprising a ramp and a robot is configured such that the structural unit and the ramp member work in coordination to allow traversability of the structure.
  • Figure 59 shows the mortar ladle tool 59100 in use. It has been picked up from the tool storage device 59200 and is being held above a trough 59300 of mortar. This trough 59300 may be filled manually, or in this instance has been positioned below a larger store of mortar 59400. This larger store 59400 may be dry-mixed and fed with a water supply, as is typical on many construction sites. The large store 59400 may be controlled using a timer, by measuring the depth of the trough 59300 below, or by receiving instructions from external control source e.g. a robot or computer.
  • external control source e.g. a robot or computer.
  • the trough 59300 and mortar dispensing nozzle on the robot 59500 may be designed so that the robot can eject any remaining mortar back into the trough e.g. the nozzle protrudes sufficiently over the edge of the trough.
  • the robot 59500 can completely empty and fill itself with a known quantity of mortar e.g. one ladle-worth without any additional measuring devices.
  • the robot 59500 would lower the gripper until the hollow element of the tool 59100 is submerged, tilt the gripper back and raise the gripper such that a portion of mortar is raised from the trough.
  • the robot 59500 would then proceed to empty the mortar into the storage device on board the robot 59500.
  • the gripper may be oscillated to assist the flow of the mortar by taking advantage of its shear thinning properties.
  • Figure 60 illustrates the use of the mortar ladle attachment 60100 that enables the robot 60200 to fill its own mortar store from a passive supply of mortar such as a trough.
  • the attachment 60100 is illustrated here being held between the clasps of the gripper of the robot 60200.
  • the mortar ladle 60100 is being manipulated by the robot gripper and arm to pour mortar into the mortar container in the main chassis of the robot 60200.
  • the robot 60200 may use small oscillations in the rotational joints of the robot arm to assist the flow of mortar by taking advantage of its shear thinning properties.
  • Figure 61 illustrates a tool 61100 which may be clasped by the robot’s gripper to fill its on board store with mortar without outside assistance. It comprises a top section 61110 which is similar in width to a standard brick. It has features 61120 on each outside face which may be areas of high friction material or physical indentations or protrusions, to facilitate the tool 61100 being held firmly by the gripper. There is a hollow, enclosed part 61130 with an opening in at least one side (here illustrated with a diagonal opening at one end). This end may be designed in conjunction with the opening to the robot’s mortar storage container to ensure a snug fit or reliable transfer of material.
  • This hollow section 61130 is attached to the upper section 61110 with a jointing element, which may be detachable from either other section to change the relative positions of upper and lower sections e.g. using a longer connecting element.
  • the whole assembly functions in a similar manner to a ladle and is used to facilitate lifting mortar out of one storage vessel and conveying it to another.
  • the hollow section 61130 may be sized appropriately so it is a similar volume to the onboard container of a robot, which may in turn be sized appropriately to be enough mortar for one or more bricks. When not being gripped by the robot, the tool may be stored in a storage device 61200.
  • the rack 61200 illustrated here is designed with a flat top with two protrusions which allow the tool to be slotted between the protrusion.
  • the protrusions may have angled edges to allow the tool to be more easily inserted into the device.
  • the device 61200 may incorporate a fiducial marker to allow a robot to more easily identify the device’s position.
  • the tool as described above may be the ladle configured to collect connecting material.
  • the robot may be configured to fill the ladle with connecting material from a connecting material container and transfer the connecting material to the connecting material storage.
  • Figure 42 illustrates different examples of fiducial markers 42001 42002 42003 42004 42005 42006 that may be embedded onto bricks or blocks.
  • the markers 42001 42002 42003 42004 42005 42006 would be designed with corresponding algorithms which enable the robots to easily detect them using their visual system.
  • the purpose of these markers 42001 42002 42003 42004 42005 42006 is to enable the estimation of the position and orientation of the brick by comparing the known pattern and its size to its appearance from the position of the robot. It may also be used to uniquely (or semi-uniquely) identify the brick, indicating its origin (e.g. the factory where it was produced and packaged) as well as the type and other information such as the time, date and batch made.
  • markers 42001 42002 42003 42004 42005 42006 may be produced through either extrusion (producing holes all the way through the brick/block), imprinting (leaving indents in the brick/block), coloured imprinting (imprinting but with different colour indents), coloured stamping (a change of the colour on the surface of the brick/block), or by applying a sticker as part of the manufacturing process.
  • the furthest left two figures show example fiducial markers 42001 42002 on a typical engineering brick that contains three central holes.
  • the next two bricks show examples of two different extrusion or imprint markers 42003 42004 that may be used.
  • the final two show the same fiducial marker, one indented 42005 and one stamped 42006.
  • the structural unit may comprise a marker enabling a system to locate the structural unit in 3D space.
  • the marker may be a visual marker.
  • the visual marker may be a fiducial marker.
  • the marker may further be configured to identify a feature of the structural unit.
  • the structural units as described herein may all comprise the markers as described in the preceding two paragraphs.
  • the automated assembly system may comprise a structural unit supply point.
  • the structural unit supply point provides a supply of structural units, such as bricks.
  • the structural unit supply point should be accessible to the robots from the structure.
  • the structural unit supply point may enable the robots to obtain bricks one or many at a time.
  • the structural unit supply point needs to be easily accessed by the structural unit supply delivery mechanism e.g. truck, crane, or forklift.
  • a collection of structural units may be provided as a plurality of layers of structural units, referred to herein as pallets.
  • the pallet arrangements can be achieved using full-bricks or cut- bricks of differing shapes and sizes.
  • the bricks may stacked in alternating orientations to allow the bricks to interlocking through gravity-induced friction.
  • the layers may also be separated by a sheet material such as paper, card or plastic sheet.
  • the pallet size and arrangement can vary. The larger the pallet, the greater the autonomy of the overall system - e.g. a pallet could be pre- loaded in the factory with all the bricks required for a given structure (e.g. a whole house), removing the need to resupply the automated assembly system with additional pallets during the assembly process.
  • the automated assembly system may comprise a staircase to allow the robots to access the upper levels of a pallet.
  • This staircase may be provided using the structural units themselves: a plurality of the layers of structural units in a pallet will each comprise less structural units than the layer on which it rests. In this way, the pallet could be considered an‘incomplete’ pallet, as it contains less structural units than would be included in a pallet by legacy structural unit suppliers.
  • the automated assembly system may comprise an additional staircase system that is set down beside the pallet to allow the robot to climb to the top of a complete pallet. This ensures that the system can be used with structural units supplied by legacy structural unit suppliers.
  • a dedicated container or special large pallet can be used to transport the structural units, such as bricks, from the factory to the site.
  • the dedicated container may include an inverse staircase feature.
  • the inverse staircase feature ‘completes’ the pallet.
  • the inverse staircase feature extends into the space in a layer of structural units for which no structural unit is present, thereby preventing the structural units from moving around in the container when the structural units are transported.
  • Figure 14 shows a perspective view of an exemplary pallet of bricks 14330 which have been specially prepared to allow robot access.
  • the bricks are arranged into a standard pattern. These are placed on a pallet or structural member to allow easier transportation. Bricks have been left out or removed from this arrangement to allow a natural staircase in once brick increments leading up one side of the pile, to allow the robot to reach all the levels.
  • a filler piece 14340 consisting of a shaped solid body, for example made from foam, timber, or metal is inserted to fill this void. The filler piece helps keep the bricks in their proper positions during transportation, and makes the whole pile in a regular box volume.
  • Figure 15 shows the above pallet 15330 after it has been packed.
  • the filler piece 15340 has been put in place, and the entire ensemble has been strapped together with bands 15350-1 to secure it in place, and may also be covered with a plastic film to keep it protected from moisture.
  • the addition of the filler piece keeps the otherwise unstable form secure during transport and allows the stacks to be tessellated with one another neatly.
  • Figure 16 shows an exemplary large container for the transportation and storage of a large volume of bricks.
  • the unit consists of a structural platform, with removable or hinged side pieces 16380-1.
  • the unit has integrated features to allow easy lifting 16360-3 by an external device such as a crane.
  • It also has a built in or modular attachment staircase 16390 to allow robots to climb up to the top of the brick pile and retrieve bricks.
  • the end of the staircase is connected to the rest of the build area with dedicated pathway 16370, to assist the robots to gain access to the pile. This is shown here integrated into one of the side panels which has been folded down, but may also be a modular attachment.
  • the automated assembly system may comprise a pallet lift, on which pallets can be placed.
  • the lift is positioned such that it may raise the pallets to a position wherein the top of the pallet is accessible to the robot from the top of the structure.
  • the lift need not be next to the structure.
  • There may be a raised pathway that enables robots to manoeuvre from the structure to the point at which the lift raises the pallets.
  • the staircase design of the structural unit pallet is not required as the top of the pallet is directly accessible from the structure.
  • Figure 54 shows a diagram of the bricklaying robot system used in conjunction with a height adjustable material supply point platform 54330.
  • the purpose of this material platform 54330 is to remove the need for robots 54100 to journey down to the ground each time they require additional bricks or mortar.
  • the platform 54330 is made to rise such that it is always level with the top course of bricks, so that robots can easily transition between the two. This may be achieved using a scissor lift, piston or other similar method.
  • the entire platform 54330 may be mounted on wheels or tracks to allow it to be easily transported, or position itself relative to the structure using its own motors. In this case, there are two protruding platforms 54010 extending out from the main platform, acting as bridges to the brick face.
  • These bridges 54010 may be height adjustable to allow fine tuning with the precise level of the brick wall. They 54010 may also be positioned so the bridge is parallel to the wall face and sweep around in a curve, allowing the robot to more easily change direction at high speed.
  • the path the robot takes on the bridges 54010 and platform 54330 is illustrated with a band of differentiated material which may serve the function of localisation (e.g. using light or other sensors to detect the band) or for charging the robot using a contact between this band and the robot (e.g. using brush connectors).
  • a pallet of bricks 54340 is placed on the ground ready to be loaded onto the raised platform.
  • This independent platform 54350 may also comprise of a separate pallet element on which the bricks may be transported to the site.
  • the lifting component of the platform may use grippers or protruding elements to engage with this pallet to lift it to the required height.
  • the main platform 54330 may be designed to allow it to automatically reload the brick pallet 54340 or other materials by driving to the materials located on the ground and picking them up. E.g. in the illustration there is an opening in the base of the platform to allow it to position itself over a pallet of bricks.
  • There is also a mortar supply point located on the platform 54330 (this could also be a tray of mortar as described elsewhere).
  • the platform 54330 may also have any number of other devices to assist with the build such as charging stations, wall tie supply points and pointing tool end effectors.
  • a platform for providing building material at varying heights for use with an assembly system for assembling a structure out of a plurality of structural units.
  • the height of the platform may be adjustable, wherein the platform is preferably configured to adjust its height such that it is always level with a top level of the structure.
  • the platform may comprise a movement system to move the platform about the structure.
  • the platform may comprise an autonomous movement system to reposition itself about the structure.
  • the platform may further comprise a bridge configured to provide a path for a robot to move between the structure and the platform.
  • the platform may comprise a pallet loading member.
  • the pallet loading member may be configured to load a pallet of structural units.
  • the pallet loading member may be configured to maintain the top layer of structural units of the pallet at the same height as the top level of structural units of the structure.
  • the pallets can be placed at the base of the staircase design described above which is easily accessible to delivery trucks and cranes.
  • the staircase design of the structural unit pallet is not necessarily required, as the top of the pallet may be directly accessible from access points on the staircase.
  • Figure 17 shows a perspective view of a storage area and integrated staircase for bricks on site.
  • the system consists of a flat platform, an integrated or detachable staircase unit 17390, an integrated or detachable robot walkable pathway 17370 leading to the rest of the build area, and a pack of bricks 17330.
  • the storage area would be set up in position such that the robots in the system are aware of its location. Bricks can be added in whole packs at a time - they are simple placed on the platform.
  • the integrated staircase allows the robots to climb up and access the high levels. By removing bricks in a deliberate order e.g. picking those furthest away on each level, and working down level by level, the pack of bricks always remains traversable during the build.
  • the robots can monitor the level of the stack and given notification when more bricks are required.
  • Figure 34 illustrates a ramp structure 34100 that enables wheeled access to each layer of a pallet 34330 of bricks or other rectangular cuboidal discrete construction units.
  • the left figure illustrates the structure in isolation and the right figure illustrates the structure 34100 with an example pallet 34330 of bricks.
  • the structure 34100 comprises two flat regions, on the far right of each figure, which are used as access pathways for the robots to leave and approach the structure 34100. These access pathways lead up to a region of alternating ramped and flat surfaces which form a right-angled“spiral”.
  • the ramped surfaces on the outside edge of the structure 34100 enable wheeled access to higher levels and the flat surfaces on the inner side of the structure 34100 enable wheeled access on to the pallet 34330 of construction material.
  • the right-angular“spiral” of the ramped region is shaped such that it neatly fits the perimeter of the pallet such that there is minimal gap between the flat surfaces and a given layer of the pallet 34330 of materials.
  • the structure 34100 may be designed in such a way to facilitate being lifted over the top of a pallet 34330 which has been placed on the ground, e.g. in one piece or with grab handles.
  • This structure 34100 may also be broken down into any number of modular parts. Eg., four large pieces which align together to enclose the brick pallet 34330 - in this case these parts may be rearranged into a different format, e.g. end to end, to better suit other sizes of brick pallet 34330.
  • the structure may in fact be composed of many numerous parts, for example similar units as the bricks themselves, combined with the“passive ramp” part.
  • the automated assembly system may comprise an additional pathway on which the robots may manoeuvre.
  • the additional pathway may, for example, be placed between the structure and a supply point, or between the structure and a charging point.
  • a pathway is placed between the structure and a pallet, such that the pallet may be placed away from the structure in a location that is easily accessible for pallet delivery systems.
  • the additional pathway may consist of modular pieces which can be fitted together to create a pathway of any length and to any direction.
  • the pathway may include turns and/or stairs to allow the pathway to reach any destination, and to avoid any obstacles.
  • the pathway may include bifurcations to provide paths to different parts of the automated assembly system.
  • a pathway from a first point on the structure may bifurcate into four different paths - the first branch leading to a material supply point; the second branch leading to a charging station; the third branch leading to a maintenance point; and the fourth branch leading to a second point on the structure, different from the first point on the structure.
  • the surface of the pathway may be similar to the top surface of the brick type being used for construction.
  • the surface of the pathway may have a standard surface, designed to be manoeuvred by robots using different feet.
  • the automated assembly system may comprise a reshaping point, accessible to the robot.
  • This reshaping point may be used to reshape structural units as required.
  • a reshaping point could be placed near a brick supply point, and used to cut bricks as required.
  • the reshaping point may comprise a powered circular or band saw fixed in place.
  • the robot may connect the structural unit to the reshaping point, the reshaping point then reshapes the structural unit, as required, and returns the brick to the robot.
  • the reshaping point may be configured such that the robot may hold bricks up to a blade to cut them to specified shapes (e.g. half bricks, angled bricks etc.). This would mean more onsite equipment is required, but would allow more brick customisation at the point of use, and hence less advance planning in the factory.
  • the automated assembly system may comprise a connecting material supply point.
  • the robot comprises a connecting material storage and delivery system.
  • the connecting material storage and delivery system comprises a connecting material container for holding the connecting material used to lay a brick.
  • the automated assembly system may comprise a connecting material supply point.
  • the connecting material supply point comprises a specially designed connecting material silo that interfaces with the robot’s connecting material storage and delivery system.
  • the connecting material silo is positioned above a walkable pathway for the robot.
  • the connecting material silo comprises a nozzle that hangs down over the pathway at a height accessible to the robot. The robot is able to walk beneath the connecting material silo nozzle and lift its body.
  • the connecting material silo nozzle enters an opening in the top of the robots connecting material storage and delivery system, for example the top of the connecting material container.
  • the connecting material storage and delivery system opens as the robot raises the main beam.
  • a seal Surrounding the opening in the connecting material storage and delivery system is a seal that ensures an air tight fit between the robot container and the silo nozzle.
  • the seal may be made of a flexible material such as rubber.
  • a sensor such as a proximity sensor on the side of the silo nozzle detects the presence of the robot and triggers the connecting material to flow from the silo nozzle in to the robots canister.
  • the connecting material silo detects when the robots canister is full using, for example, a mechanism similar to that found in petrol pumps.
  • a small tube in the silo nozzle is connected to a suction device such as a venturi. Whilst the robot canister is being filled air flows through this small tube. Once the canister is full the air tube is blocked by the connecting material and the change in suction is detected triggering the connecting material silo to close its nozzle.
  • Another approach is to use pressure sensors in the feet of the robot to detect the change in weight of the robot. Once the weight of the robot corresponds to the weight of the robot when fully laden with connecting material, the robot can trigger the connecting material silo to close the nozzle.
  • FIG. 6 shows a perspective view of an exemplary connecting material storage unit 6220, robot unit 6000 and custom dispenser apparatus 6230 which interfaces between the two.
  • the connecting material storage unit is a large hollow container, mounted above the ground. It may have an internal auger screw or paddle to assist with connecting material mixing, and integrated sensors and control program to monitor the quantity, moisture or chemical content of the connecting material.
  • the storage unit is positioned above a walkable pathway 6240 for the robot, such that the robot can walk along and stop underneath the storage unit.
  • the unit has an opening through which connecting material can flow from the unit into the robot. To do this, it passes through a flow valve and nozzle, which is connected to a pressure or distance sensor positioned to interface with the robot.
  • the nozzle and the opening of the top of the robot are designed in conjunction, such that the nozzle will fit snuggle into the robot’s opening 1080.
  • the unit’s height is such that the robot can lower itself on its legs 1010-1, position itself underneath the unit’s nozzle, and then raise itself up on its legs, thus inserting the nozzle into its opening. This would automatically begin connecting material flow, through contact or interface with a sensor on the storage unit. Connecting material flow may be measured through a variety of ways such as flow sensor in the nozzle 5200, depth sensor in the robot’s container, or strain gauges built into the robot’s legs detecting the change in the robot’s mass as connecting material is delivered. Once sufficient connecting material has been transferred, the robot can lower itself on its legs, thus stopping the connecting material flow and retracting the nozzle from the opening, and then walk onwards to lay a brick.
  • Figure 7 shows perspective views of an exemplary robot refilling itself with connecting material from an exemplary storage unit 7220.
  • the first view shows the robot lowering itself on its legs and positioning itself underneath the storage unit’s nozzle 7230.
  • the second view shows the robot having raised itself up on its legs, thereby inserting the storage unit’s nozzle 7230 into its opening.
  • the opening’s cap 4120-1 has been pushed apart by the nozzle as it has been inserted.
  • the sensor on the storage unit has made contact with the robot’s body, thereby initiating the connecting material to start flowing. (See above for details).
  • the automated assembly system may comprise a wall-tie supply point.
  • Wall-ties are an integral part of brick outer-leaf structures. They ensure that the wall is structurally safe by securing it to the inner-leaf.
  • a wall-tie supply point comprises a wall tie dispensing system.
  • the wall tie dispensing system comprises a stack of wall-ties contained in a cartridge like container. At the base of the cartridge like container is an opening and a mechanism (active or passive) that pushes out the wall-tie at the bottom of the stack. This enables a robot with the appropriate gripper to take the wall-tie from the cartridge. When the wall-tie is removed the stack, the wall- ties fall under gravity to fill the place of the removed one.
  • Figure 52 shows a flowchart of illustrating the overall build system architecture integrated with a brick production factory, essentially showing how the entire supply chain may be automated from the bricks production to its placement in the walls of a building.
  • This brick production factory may be located on site (if the local materials are suitable or by necessity e.g. in remote / lunar / martian environments), or remotely in a dedicated industrial facility.
  • the central control is the build planning software for managing the on site robots. This central control receives the building design and automatically calculates the material schedule required for the build and sends it to the brick production factory to produce the required materials.
  • the central control also communicates the way in which the bricks should be packaged to best suit the assembly by the robots onsite - e.g.
  • markers are used to manage the position of each brick, these may be logged by the controller to be used once they arrive onsite.
  • the central control may also receive other variable inputs such as market demand for that building type, or weather predictions in the site locality. E.g. if bad weather is expected, the operation may speed up to finish before this occurs, or the available robots and materials might be diverted to another site where there is better weather and work can proceed without hindrance.
  • the central control also plans the number of robots used for each build, and may keep track of each robot’s status, location and maintenance condition. Thus a large robot fleet can be managed across several sites.
  • Materials and robots may be transported to the site using autonomous vehicles or personnel driving conventional vehicles who receive instructions from the central controller. Once the materials are on site, the assembly robots start work. They receive instructions about the build from the central control, and feedback information on the state of the build and the actual weather conditions onsite. Production and packaging may be adapted dynamically on receipt of this information, as well as more updated weather predictions. All data passing through the central control can be logged and used to improve the processes in future build sequences, using artificial neural networks or other data analytic methods. The future building designs may be optimised as a result of this data.
  • the automated assembly system may comprise onsite or offsite building material production system (e.g. brick forming machine from local materials, or a link to an offsite factory, or similarly an onsite mortar mixer (dry silo) and the link to an offsite mortar factory.
  • brick manufacture may be controlled by exchanging data between overall control program and individual robots. This allows management of materials according to a just-in-time delivery if required. This is particularly useful if the construction site is constrained, with limited space or access to supply materials.
  • bricks may be produced in small runs for specific build projects. This allows the factory to plan their production schedules accurately to minimize stocks.
  • the automated assembly system via communication with the material production system, may be configured to generate structural units and/or connecting material on demand.
  • the material production system may be configured to receive a number of structural units and/or connecting material required for a given structure.
  • the material production system is configured to be in communication with the automated assembly system and individual robots within the automated assembly system.
  • the automated assembly system may be configured to forecast how many/much structural units and/or connecting material are/is required at a given time.
  • the forecast may be based on any one or more of the following: the amount of space near the structure being constructed (so that there is enough space for the structural units and/or connecting material to be delivered), the number of robots and the speed at which they are constructing the structure, the total structural units and/or connecting material required, the time it takes to deliver structural units and/or connecting material to the structure being constructed, the speed of making the structural units and/or connecting material, and/or the availability of materials available to make the structural units and/or connecting material.
  • the assembly system for assembling a structure out of a plurality of structural units may comprise an assembly control program; a building material production system, wherein the assembly control program is configured to manage the production of building materials of the building material production.
  • the assembly control program may be configured to generate a production schedule and transmit the production schedule to the building material production system.
  • the production schedule may be based on any one or more of the following: total amount of building material required, total amount of each building material required, total amount of building material currently accessible by a robot, total amount of building material already present in the structure, the rate at which the robot is assembling the structure, the amount of free space surrounding the structure, the current weather, a forecast of the weather, and/or market demand for building materials.
  • the assembly control program may be configured to manage the production of building materials such that a/the robot always has access to building materials.
  • the building material production system may be onsite to the structure.
  • the building materials may comprise structural units and connecting material and in particular may be bricks and mortar.
  • Figure 55 shows a diagram illustrating an example apparatus setup for a complete build.
  • a human worker On the far left is a human worker. They may be monitoring the build or sending high-level system commands using the tablet computer device that is situated in the hands of the worker.
  • the helmet may be equipped with augmented reality capabilities, displaying to the worker extra information about the build overlayed onto the scene, for example planned robot paths or the battery status of robots.
  • the settings for said augmented reality scene may be controllable from the tablet.
  • To the right of the worker is the brick/block material supply 55330, in pallet form, with a robot 55600 illustrated removing a brick from the top of the pallet.
  • a staircase is formed into the pallet by removing pairs of bricks such a continuous path is made available for the stepping robot from the access ramp to the top of the pallet.
  • An access ramp may be used to facilitate the robots motion from the bottom of the pallet to the required level of bricks.
  • An access pathway is situated at the base of this staircase to the right.
  • a square representing a fiducial marker that indicates to the robots the position and location of the material supply point. We see other fiducial markers illustrated on the floor near the main structure and on the inner cavity wall.
  • a mortar supply point 55500 Next to the access ramp is also placed a mortar supply point 55500, and three other supply points, which may comprise a battery changing station, a wall-tie store and a gripper attachment/end effector store.
  • To the right of the flat access ramp is the sloped access ramp 55200 that gives the robots 55600, 55400, 55300, 55100 wheeled access to the main structure.
  • the automated assembly system may comprise a robot charging point.
  • a robot charging point allows the robots to charge their batteries autonomously.
  • the robot charging point may be powered either by the mains or a portable generator, e.g. petrol or solar power.
  • the robot charging point may be an area with a number of docking stations and respective pathways to enable robot access. Alternatively, the robot charging point may include only one docking station.
  • the docking stations could allow access to the rear of the robots main beam.
  • the docking station comprises a conductive contact that connects with the charging ports on the rear of the robot’s body. In this way, the robot is able to walk directly into the docking station to connect with the conductive contact.
  • the robot charging point Upon detection of the robot the charging station initiates the charging process.
  • the robot charging point could also use wireless charging through induction.
  • robot charging points could also allow batteries to be exchanged.
  • the battery would be a removable part of the robot, for example, a removable part of the robot body (e.g. snap fit or release catch). Batteries could be deposited onto vacant charging racks or slots, and re-charged ones picked up in place.
  • a robot charging point may be included in other parts of the automated assembly system.
  • power may be provided via a staircase, a lift, and/or a pathway.
  • a robot may include a connection on its feet to connect with the charging point on the staircase, lift, and/or pathway.
  • the charging point may connect with the robot at a plurality of points on a part of the automated assembly system. By including connections on both feet, the robot will always be in contact with the staircase, lift, and/or pathway whilst it manoeuvres around them. Therefore, the robot will continually charge. Alternatively, the robot may charge via induction.
  • the robots are configured to communicate with communicating parts of the automated assembly system in order to share information about their status and their actions, and receive information from the other communicating parts of the automated assembly system.
  • the other communicating parts of the automated assembly system may be other robots, or any other part of the automated assembly system which communicates with the robots, such as a central computer.
  • Communications in the automated assembly system may be wireless.
  • Wireless communications may be based on Bluetooth, Wi-Fi and/or broadband cellular network technology, for example.
  • the robot may also integrate aerials or receivers for wireless communication with other robots or location systems via Wi-Fi, Bluetooth, laser or infra-red etc.
  • Communication may also, or alternatively, be achieved through a physical connection to a part of the automated assembly system.
  • a staircase or pathway may include a connection which connects a robot to a communication channel as the robot manoeuvres on the staircase or pathway.
  • a charging point may include a connection which connects a robot to a communication channel. Communication may be achieved via a connection used to transmit power to the robot.
  • the network structure with which communicating parts of the automated assembly system communicate with other communicating parts of the automated assembly system may comprise any network topology, some examples of which are described below.
  • a communicating part of the automated assembly system may be configured to communicate with other communicating parts of the automated assembly system directly.
  • Each communicating part of the automated assembly system in the system may be able to communicate with each other communicating part of the automated assembly system directly.
  • a communicating part of the automated assembly system may only be able to communicate directly with a subset of the communicating parts of the automated assembly system.
  • the subset of communicating parts of the automated assembly system with which a particular communicating part of the automated assembly system may communicate may depend on the position or type of the communicating parts of the automated assembly system - for example, whether it is another robot, or a charging station, and where the robot or charging station is in relation to the part of the automated assembly system that wishes to communicate.
  • robots may communicate with other robots using a distributed full-mesh network, where each robot communicates directly with each other robot.
  • a communicating part of the automated assembly system may be able to communicate with other communicating parts of the automated assembly system indirectly via the communicating parts of the automated assembly system with which it may communicate directly - for example, through a central computer. This creates a centralised network where communications between two communicating parts of the automated assembly system pass through a third communicating part of the automated assembly system.
  • the communicating parts of the automated assembly system may be configured to communicate via mixed direct and indirect communication.
  • This approach uses some direct communication between communicating parts of the automated assembly system whilst also using indirect communication between communicating parts of the automated assembly system - for example, using direct communication between robots and indirect communication between robots other communicating parts of the automated assembly system (such as a material supply point that is configured to communicate with the robots) via a central computer.
  • Figure 33 contains three diagrams of the possible network connections between the robots and a central controller. The arrows indicate information pathways transmitted either by Bluetooth, Wi-Fi or cellular network. The upper diagram shows a fully connected mesh network where each robot 33000-4 is connected with every other robot.
  • the middle diagram shows a centralised start network where all robots are connected to the central controller 33810 and can only communicate with each other through this central station.
  • the final diagram shows a fully connected mesh network where all robots can communicate with each other and a central controller. This last option enables the advantages of direct communication with the option of being able to control all robots simultaneously, for example allowing for a system wide shutdown in an emergency.
  • a robot as described above may be configured to disassemble a structure - for example, the assembly process may also be performed in reverse. In this way, a structure may be disassembled in a controlled and automated fashion.
  • the structural units may be sorted into piles of different components, for example bricks of different sizes and shapes, or the sand and general rubble of decomposed mortar.
  • sorting bins or other hollow containers may also be used to sort materials.
  • the tops of the containers may be accessed by the robot using ramps. These ramps may be separate structures (as previously described) or built into the structure of the containers.
  • the automated disassembly process may also be carried out in a more destructive manner, for example by the robots destroying the base of the structure by chipping, drilling and cutting, thus causing the structure to collapse in a controlled or semi-controlled manner.
  • the constituent parts would then be sorted by the robot.
  • This principle could also be applied to disassemble and sort structures composed of discrete parts, such as a pile of rubbish or other debris.
  • the pile of rubbish would be accessed from the ground level or at various other levels using ramps.
  • the robot would access the various layers of the rubbish pile, picking up each item in turn and be able to store one or several items in the chassis of the robot.
  • Each item can be classified into material or object type using the robot’s vision system and a classification algorithm, for example a convolutional neural network.
  • the robot would then manoeuvre down the ramp and or along the ground level to the sorting containers. It would then manoeuvre up the ramp to the top of the container and deposit the discrete item or items of rubbish into each container.
  • pile of rubbish composed of discrete items could be sorted into various materials and item classifications.
  • the pile of rubbish would only be one, two or three‘layers’ high, such that the robot would be able to access all discrete items without requiring an additional access ramp or manoeuvring over the structure itself.
  • a connecting material delivery system may be included on another robot.
  • a robot according to aspect 1 wherein the robot is configured to manoeuvre around the structure by traversing and/or climbing the structure.
  • a robot according to any preceding aspect comprising: an effector, preferably configured to releasably couple to a structural unit, and preferably configured to move along a single axis, and more preferably the single axis is the vertical axis; and a means for traversing and/or climbing the structure.
  • a robot according to any preceding aspect comprising a track set and preferably the track set is no wider than a structural unit.
  • a robot according to any preceding aspect wherein the robot comprises: a robot body; and a first foot coupled to the robot body and a second foot coupled to the robot body, wherein the first and second feet are configured to move relative to the robot body and each other.
  • a robot according to aspect 3 wherein the first and second feet are coupled to opposite sides of the robot body.
  • a robot according to aspect 4 wherein the first and second feet are coupled to the opposite sides of the robot body by legs, wherein the leg of each foot is configured to move in a respective movement plane, horizontally and vertically relative to the robot body, wherein the sole of each foot extends horizontally towards the movement plane of the opposite leg.
  • a robot according to aspect 5 wherein at least a portion of the legs are spaced apart to allow a structural unit to pass between them as the legs pass each other.
  • the robot further comprises an effector coupled to the robot body.
  • the effector is configured to releasably couple to a structural unit.
  • a robot according to aspect 7 or 8 wherein the robot is configured to arrange the robot body and effector so that the robot centre of mass is over one foot, then lift the other foot, then move the raised foot past the stationary foot whilst the robot body and/or main effector are moved in the opposite direction, then place the raised foot down.
  • the robot comprises a structural unit positioning system.
  • the structural unit positioning system comprises proximity sensors placed on the effector.
  • the structural unit positioning system comprises a stereoscopic camera placed on the robot body. 13A) A robot according to any one of aspects 11 to 13, wherein the structural unit positioning system is configured to read a marker on a structural unit to determine the position and/or orientation of a structural unit, and preferably the marker is a fiducial marker, and preferably the robot comprises a camera to read the marker.
  • a robot according to any preceding aspect wherein the robot comprises a structural unit position correcting system, wherein the structural unit position correcting system comprises at least one structural unit position sensor and at least one structural unit positioning device.
  • the structural unit position device is a tapping device.
  • the structural unit position correcting system is configured to change the position of the structural unit by tapping and/or vibrating on the structural unit.
  • the at least one structural unit position sensor is configured to check the position of the structural unit, and the at least one structural unit positioning device changes the position of the structural unit.
  • the structural unit is a masonry brick.
  • a robot according to any preceding aspect further comprising the structural unit, wherein the structural unit is preferably a masonry brick.
  • the robot is configured to pick up bricks and connecting material from a material supply point, manoeuvre around the structure to a position on the structure, apply the connecting material, place the brick, and then climb back to a material supply point or a charging point.
  • the robot comprises a connecting material storage and delivery system.
  • the connecting material storage and delivery system comprises a connecting material container connected to a nozzle.
  • a robot according to aspect 22, wherein the nozzle is a detachable element that is detachable from the remainder of the connecting material storage and delivery system.
  • the connecting material storage and delivery system is configured to build up pressure behind the nozzle cover before releasing the connecting material.
  • the connecting material storage and supply system is configured to interface with a connecting material supply point, wherein the moveable cap is configured to open when the connecting material supply point is connected to the connecting material container.
  • the nozzle is configured to rotate around a vertical axis.
  • the horizontal position of the nozzle is fixed relative to the robot body such that movement of the robot body in a horizontal direction moves the nozzle in a horizontal direction.
  • the nozzle is configured to move vertically relative to the robot body.
  • the additive is water
  • the connecting material storage and delivery system comprises at least one sensor to sense the moisture content of the connecting material in the connecting material storage and delivery system, wherein the connecting material storage and delivery system is configured to control the moisture content of the connecting material in the connecting material storage and delivery system by adding water from the reservoir.
  • the additive is added to the connecting material as it is expelled from the nozzle, wherein the additive increases the rate at which the connecting material sets.
  • a robot according to aspect 41 wherein the robot balancing system uses a measurement of at least one of pressure, strain, and changes in angular momentum to balance the robot.
  • the robot comprises a collision avoidance system.
  • the robot comprises a robot control program, wherein the robot control program is at least partially controlled by an assembly control program.
  • the robot comprises at least one positioning system for determining the robot’s position on the structure.
  • the positioning system determines the robot’s position on the structure by calculating a change in the robot’s position based upon the movement of the robot.
  • the positioning system comprises a sensor for determining a model of the robot’s local environment, wherein the robot is configured to compare the model of the robot’s local environment with a model of the structure to determine the robot’s position on the structure.
  • the robot is configured to determine a map of an area of the structure greater than the locality of the robot by determining a map of the structure in the locality of the robot at each of a plurality of positions on the structure.
  • the robot is configured to compare the determined map with a model of the structure in order to determine the robot’s position on the structure.
  • the robot is configured to obey valve constraints which determine in which directions the robot may travel on a path.
  • the robot is configured to perform checks at checkpoint positions on the structure.
  • the robot comprises a power source, wherein the robot is configured to charge the power source as it manoeuvres around additional hardware in the assembly system.
  • the robot is configured to communicate with other robot’s using a distributed full-mesh network.
  • a system for assembling a structure out of plurality of structural units wherein the system comprises at least one robot, preferably a plurality of robots, according to any preceding aspect.
  • a system for assembling a structure out of a plurality of structural units wherein the system comprises at least one robot, preferably a plurality of robots, configured to manoeuvre around the structure.
  • the robot further comprises an effector configured to releasably couple to a structural unit.
  • a method of organising at least one robot to assemble a structure out of a plurality of structural units comprises: receiving a model of a structure; determining a structural unit layout model of the structure; and determining a sequence of assembly stages such that the structure is accessible to the at least one robot at all assembly stages.
  • the received model of the structure is a 3-dimensional model of the structure.
  • the structural unit layout model of the structure determines the position of each of a plurality of structural units in the structure.
  • determining the sequence of assembly stages includes determining the order for laying the structural units.
  • the method further comprises determining a flow control for a plurality of robots.
  • determining the flow control comprises determining the position of a valve on a path on which a robot manoeuvres between points in the automatic assembly system, wherein the valve determines the direction of movement the robot may take.
  • a method of organising at least one robot in an assembly system comprising: setting a valve on a path on which a robot manoeuvres between points in the automatic assembly system, wherein the valve determines the direction of movement the robot may take; communicating the position of the valve to the robot.
  • the method further comprises determining the path on which the robot manoeuvres between points in the automatic assembly system.
  • the valve is set at a point on the path, and the valve determines the directions in which the robot may move from that point.
  • a staircase system according to aspect 73 or 74, wherein the staircase comprises a plurality of steps between a plurality of access levels, wherein the access levels are at heights corresponding to every three steps.
  • An assembly system for assembling a structure out of a plurality of structural units wherein the system comprises: a bypass system; at least one robot configured to manoeuvre between points on the structure via the bypass system.
  • a bypass system for use with an assembly system comprising at least one robot.
  • An assembly system for assembling a structure out of a plurality of structural units comprising: a module by which a robot may enter the structure or a module by which a robot may exit the structure; at least one robot configured to enter or exit the structure via the out of structure entry- exit system. 79) A module by which a robot may enter the structure or a module by which a robot may exit the structure for use with an assembly system comprising at least one robot.
  • the module comprises a ramped path between multiple levels of the structure, and preferably the ramped path comprises a plurality of inclined surfaces.
  • An assembly system for assembling a structure out of a plurality of structural units wherein the system comprises: a first and second module by which a robot may enter the structure or a module by which a robot may exit the structure according to any one of aspects 79 to 84; at least two robots configured to access or exit the structure via the modules, wherein the at least two robots exit via the first module and exit via the module.
  • a ramp member for placement on a structure comprising a plurality of structural units and allowing a robot to traverse from one layer of structural units to another, wherein the ramp member comprises an inclined plane, wherein the ramp member is preferably configured to allow a robot to traverse the ramp member, and preferably a height of the ramp member is approximately an integer multiple or integer factor of the height of one of the structural units, and preferably the height of the ramp member is approximately the same as the height of one of the structural units, and preferably the same width and/or length as one of the structural units.
  • a ramp member according to aspect 86 wherein the ramp member further comprises gripping points configured to allow a robot to grip the ramp member, wherein the gripping points are preferably gripping attachments, such as gripping protrusions, such as upside-down L-shaped attachments.
  • a ramp member according to aspect 86 or 87 wherein the ramp member is configured to move or be moved about the structure, and preferably configured to move itself about the structure, and more preferably the ramp member comprises a track set.
  • An assembly system for assembling a structure out of a plurality of structural units comprising: a ramp member according to any one of aspects 86 to 88; at least one robot configured to traverse the ramp member in order to traverse from one layer of structural units to another, and preferably spread a connection, and preferably place a structural unit.
  • the at least one robot further comprises an effector configured to releasably couple to the ramp member, and preferably the effector is further configured to releasably couple to a structural unit.
  • An assembly system for assembling a structure out of a plurality of structural units comprising: a ramp member according to any one of the aspects 86 to 90; a structural unit.
  • a robot according to any preceding aspect wherein the robot comprises: a robot body; a track set, wherein the track set preferably comprises one or more tracks.
  • a robot according to aspect 94 wherein the robot is configured to move up onto a structural unit via a ramp member, spread a connecting material, and place a structural unit.
  • the robot comprises a/the foot coupled to a/the robot body, and preferably the track set is coupled to the foot.
  • a/the track set is located at the bottom of the body of a/the robot.
  • a/the track set comprises two tracks, the speed of each of the tracks within the track set are independently controlled, and preferably the speed of each of the tracks within the track set are independently controlled such that the robot can turn.
  • a robot according to any preceding aspect wherein the robot comprises a further track set, and preferably the two track sets are dimensioned and spaced apart such that they are able to fit onto the length of a single structural unit, and preferably the two track sets are dimensioned and spaced apart such that they each can move relative to a/the robot body independently of the other whilst not obstructing the each other.
  • each track set is coupled to the robot body by length adjustable legs such that each track set can be raised or lowered independently, and preferably such that the robot can step up or step down a structural unit.
  • a robot according to aspect 99 wherein the robot is configured to step up on a structural unit, spread a connecting material, and place a structural unit.
  • 99B A robot according to any preceding aspect, wherein the robot is configured to step up on a structural unit, spread a connecting material, and place a structural unit.
  • 100 A robot according to any preceding aspect, wherein the robot is configured to place a structural unit, and preferably place the structural unit onto a bed of connecting material, and preferably where the connecting material is shear-thinning connecting material.
  • a robot according to aspect 100 wherein the robot is configured to: move the structural unit into a starting position, and preferably the starting position is close to a final position of the structural unit, and preferably the starting position is a positon above the final position, and preferably the structural unit with an effector is moved with an effector of the robot; agitate the bed of connecting material such that the bed of connecting material decreases in viscosity; move the structural unit into a final position; and cease agitation.
  • the agitation is conducted by oscillating the structural unit with a/the effector.
  • a robot according to aspect 101 or aspect 102 further configured to do any one or more of: receiving structural unit orientation; calculating placement trajectory; and receiving oscillation axis, oscillation frequency and/or oscillation amplitude.
  • a robot according to aspect any one of aspects 102 or 103 wherein the oscillating motion of the structural unit axis moves the structural unit towards and away from the final position of the structural unit.
  • a robot according to any one of aspects 102 to 104 wherein the robot comprises a robot body and the effector is moveably coupled to the robot body, wherein during oscillation of the structural unit the effector and structural unit move in the same direction relative to the robot body.
  • a/the effector is configured to move relative to the robot body along an oscillation axis, and preferably the oscillation axis extends towards and away from a/the robot body, and preferably a/the structural unit oscillates in rotation about that oscillation axis.
  • I l l A platform according to aspect 110, wherein the height of the platform is adjustable, and wherein the platform is preferably configured to adjust its height such that it is always level with a top level of the structure.
  • the platform comprises a movement system to move the platform about the structure, wherein the platform preferably comprises an autonomous movement system to reposition itself about the structure.
  • An assembly system for assembling a structure out of a plurality of structural units wherein the system comprises: a marker; and a marker reader, wherein upon reading the marker, a location and/or orientation of the marker or a location and/or orientation of the marker reader is determined.
  • the marker is applied to or near any one of the following: the robot, a structural unit, the marker reader, a connecting material trough, a connecting material store, a pallet, a structural unit location, an out of out of structure entry-exit system, a supply point, a platform, a building material production system, the structure, any other system component described herein, and/or any other locations the robot visits on or around the structure.
  • An assembly system according to aspect 115 or aspect 116, wherein the marker is on a robot such that the robot’s position can be determined by the marker reader, and optionally the robot’s position is transmitted to the robot.
  • the system further comprises a further marker reader, and wherein at least one of the marker readers comprises a further marker, preferably such that the relative position of the marker readers may be determined.
  • the system further comprises a controller in communication with the marker reader and at least one robot.
  • An assembly system for assembling a structure out of a plurality of structural units comprising: an assembly control program; a building material production system for producing building materials, such as a plurality of structural units, wherein the assembly control program is configured to manage production of the building materials by the building material production system.
  • an assembly system according to aspect 120 wherein the assembly control program is configured to generate a production schedule and transmit the production schedule to the building material production system.
  • An assembly system according to aspect 121, wherein the production schedule is based on any one or more of the following: total amount of building material required, total amount of each building material required, total amount of building material currently accessible by a robot, total amount of building material already present in the structure, the rate at which the robot is assembling the structure, the amount of free space surrounding the structure, the current weather, a forecast of the weather, and/or market demand for building materials. 123) An assembly system according to any one of aspects 120 to 122, wherein the system further comprises a robot configured to assemble the structure out of the plurality of structural units, wherein the assembly control program is configured to manage the production of building materials during the assembly of the structure such that the robot always has access to building materials.
  • a/the effector is configured move a structural unit about the nozzle such that connecting material is applied to the structural unit without movement of the nozzle.
  • An assembly system for assembling a structure out of a plurality of structural units comprising: a tool; and a robot configured to grasp the tool.
  • the finishing tool arm comprises a shaped tool for finishing the connecting material to provide a desired finish, and optionally, the shaped tool is removable from the remainder of the finishing tool arm, or the finishing tool arm is removable from the finishing tool body.
  • the tool is any one or more of the following: a brush, a paint dispenser, a dustpan, a nail gun, a ladle, a screwdriver, and/or an insulation board manipulation device.
  • An assembly system according to aspect 128, wherein the tool is a ladle configured to collect connecting material.
  • An assembly system according to aspect 133, wherein the robot is configured to fill the ladle with connecting material from a connecting material container and transfer the connecting material to a/the connecting material storage. 135) An assembly system according to any one of aspects 128 to 134, wherein the robot comprises an effector configured to releasably couple to a structural unit and the tool. 136) A structural unit comprising a marker enabling a system to locate the structural unit in 3D space. 137) A structural unit according to aspect 136, wherein the marker is a visual marker, and preferably the visual marker is a fiducial marker.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Manipulator (AREA)
  • Automatic Assembly (AREA)

Abstract

La présente invention concerne un robot destiné à être utilisé dans un système d'assemblage dans lequel une structure est assemblée parmi une pluralité d'unités structurales, le robot étant configuré pour manœuvrer autour de la structure.
PCT/IB2019/061303 2018-12-24 2019-12-23 Assembleur structurel WO2020136563A2 (fr)

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GB1821200.1A GB2580312A (en) 2018-12-24 2018-12-24 Structural assembler
GB1821200.1 2018-12-24
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GB201914482A GB201914482D0 (en) 2018-12-24 2019-10-07 Structural assembler

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CN115272589A (zh) * 2022-09-27 2022-11-01 江苏数字看点科技有限公司 无损融合bim模型的数据处理方法及系统
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CN111764665A (zh) * 2020-07-10 2020-10-13 上海雅跃智能科技有限公司 一种基于bim的智能爬架与外墙作业机器人系统
EP4155037A1 (fr) * 2021-09-24 2023-03-29 DAIHEN Corporation Système de production de programme de travail et procédé de production de programme de travail
CN114508241A (zh) * 2022-03-15 2022-05-17 卢运才 一种基于楼房建造专用的砌砖装置
WO2024050618A1 (fr) * 2022-09-08 2024-03-14 Groupe Réfraco Inc. Positionnement vertical de brique
CN115272589A (zh) * 2022-09-27 2022-11-01 江苏数字看点科技有限公司 无损融合bim模型的数据处理方法及系统
CN115272589B (zh) * 2022-09-27 2022-12-16 江苏数字看点科技有限公司 无损融合bim模型的数据处理方法及系统

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WO2020136563A3 (fr) 2020-08-06

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