WO2021136956A1

WO2021136956A1 - Automated building system

Info

Publication number: WO2021136956A1
Application number: PCT/IB2019/061451
Authority: WO
Inventors: Ayman TRAWI
Original assignee: Medcom France S.R.O
Priority date: 2019-12-30
Filing date: 2019-12-30
Publication date: 2021-07-08

Abstract

The present invention relates to an autonomous building system based on a polar robot concept with 3-DOF (degrees of freedom), to improve the construction process of buildings. The system is a 3D printer structure (1) that is projected to cover a circular workspace with a variable height, with the purpose of improving the stability of the structure (1) and the precision of the automated construction process. In a preferred embodiment of the system, it is comprised by a crane structure (1), formed by a horizontal arm element (2) and a vertical mast (3), a connection unit that is arranged to connect the horizontal arm (2) and the vertical mast (3) in a proper way, a printing unit (5) and a control module.

Description

DESCRIPTION

AUTOMATED BUILDING SYSTEM

FIELD OF THE INVENTION

The present invention is enclosed in the field of automated building systems.

PRIOR ART

Solutions exist in the art based in concepts of robotization applied to construction industry. As an example, the patent application CN10S7862S5A discloses a tower-type three-dimensional printer comprising a tower crane, a material adding system, a control system, a manoeuvring system, a material guide pipe and a printing system. The control system is connected with the material adding system and the manoeuvring system respectively, and is used for establishing 3D construction models, controlling the printing system to print according to 3D models and for sending control commands to the manoeuvring system. The material adding system is connected with the printing system through the material guide pipe, and is used for storing building materials and conveying the building materials to the printing system. The printing system is fixed on the tower crane, is electrically connected with the manoeuvring system, the material adding system and the control system respectively, and is used for printing 3D buildings. The manoeuvring system is mounted on the tower crane, and is used for controlling motion of the tower crane and the printing system. Such architectural scheme is shared by the majority of the solution of the state of the art, however all them addresses the problem only from the perspective of the robotization and therefore disregarding important aspects related to the stability of the entire structure supporting the printing system and the precision of the construction process.

In this regard, patent application CN103790378B address the problem of the precision by actuating in the software responsible for controlling the operation of the system. Particularly, it is disclosed a building construction equipment comprising a tower crane, where a printing head is installed, and a control system. Said control system is configured to run a 3D modelling software that based on a pre-set printing precision 3D parameter and on an engineering construction model, establishes a stratified cut model that is used to program the operation of the tower crane and the printing head.

The above described solutions do not consider the system's structure stability as a base for ensuring the precision of the construction process, which represents a major limitation since a proper stabilization in the coordinated movements between all the structural elements of such systems cannot be, therefore, ensured.

The present solution intended to innovatively overcome such issues, improving the stability of the structure and the precision of the automated construction process.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention an autonomous building system based on a polar robot concept with 3-DOF (degrees of freedom), to improve the construction process of buildings. The system is a 3D printer structure that is projected to cover a circular workspace with a variable height.

In a preferred embodiment of the invention, the system is comprised by a crane structure, formed by a horizontal arm element and a vertical mast, a connection unit that is arranged to connect the horizontal arm and the vertical mast in a proper way, a printing unit and a control module.

The connection unit comprises a rotation mechanism formed by a slewing unit that is installed in the vertical mast. The connection unit is responsible for connecting the horizontal arm element, being for that purpose comprised by at least two slewing bearings for providing rotation of the horizontal arm element around the slewing unit and by extension around the vertical mast. Said rotation mechanism is driven by a first motor. The connection unit further comprises a lifting mechanism formed by a linear ball bearing guide which is installed in the vertical mast and is configured to provide a vertical displacement along the vertical axis to the slewing unit and to the horizontal arm element connected to it. Said vertical displacement is driven by a second motor. The printing unit is installed in the horizontal arm element and is configured to move along said arm element through a closed-loop roller chain powered by a third motor.

The control module comprises a processor unit and a communication unit, wherein the processor unit is configured to operate the rotation mechanism, the lifting mechanism and the printing unit, actuating on the first, second and third motor respectively, according to operative commands received by the communication unit.

DETAILED DESCRIPTION

The more general and advantageous configurations of the present invention are described in the Summary of the invention. Such configurations are detailed below in accordance with other advantageous and/or preferred embodiments of implementation of the present invention.

In a preferred embodiment of the invention, the automated building system is comprised by a crane structure, a connection unit, a printing unit and a control unit.

According to said preferred embodiment, the crane structure is formed by a horizontal arm element and by a vertical mast. Said vertical mast is fixed to the ground by means of a base, that is projected to ensure the proper stability of the vertical mast and of the remaining elements of the system connected to it. In one alternative embodiment of the invention the horizontal arm of the crane structure comprises a counterweight installed in an end opposite to a section of the horizontal element where the printing unit moves, to avoid having high moment load. In another alternative embodiment of the invention, the base wherein the vertical mast of the crane structure is mounted is formed by four I-beams, providing a greater stability by improving the system weigh distribution and allowing the handle of high loads. In another alternative embodiment of the invention, an extension mast can be installed between the base and an end of the vertical mask. As a result, the added height is considered a dead zone where the connection unit cannot move through. On the other hand, the working area is shifted up, allowing the operation in an upper construction level, for example for building an extra floor.

The connection unit, according to the preferred embodiment of the invention, is arranged to properly connect the horizontal arm and the vertical mast ensuring the stability and precision in the coordinate movements relative to each other. To achieve that, the connection unit is comprised by a rotation mechanism and by a lifting mechanism. The rotation mechanism comprises a slewing unit that is installed in the vertical mast. Said slewing unit provides connection to the horizontal arm element and is comprised by at least two slewing bearings that are projected to provide rotation of the horizontal arm element around the slewing unit and by extension around the vertical mast. The use of at least two slewing bearings helps to support the load of the horizontal arm and to provide high precision turning. The rotation mechanism is driven by a first motor. In an alternative embodiment of the invention, the first motor powers the rotation mechanism by means of a pinion and gear mechanism. For that purpose, the slewing bear of the slewing unit works as a spur gear and a pinion and gear mesh is assembled in the horizontal arm. Yet in another embodiment of the invention, the slewing unit comprises at least two slip rings and an electric circuit adapted to feed said slip rings. In this way, infinite rotation loop of the horizontal arm in relation to the vertical mast can be guaranteed. In this embodiment, the horizontal arm element comprises coal brushes for connecting the slip rings of the slewing unit to the control module, thus allowing electricity transmission while infinite rotating process.

On the other hand, the lifting mechanism comprises a linear ball bearing guide that is installed in the vertical mast and is configured to provide a vertical displacement along the vertical axis to the slewing unit and to the horizontal arm element connected to it. Said vertical displacement is driven by a second motor. In an alternative embodiment of the invention, the vertical mast is hollow and the lifting mechanism comprises a counterweight connected to the slewing unit, for improving the balance of the crane structure. Said counterweight moves along the vertical axis in function of the vertical displacement of the horizontal arm element, by means of a roller chain installed inside of the vertical mask. This configuration allows the counterweight to move inside the hollow structure of the vertical mask, so that the load on the second motor - responsible for the vertical displacement - can be decreased.

According to the preferred embodiment, the printing unit is installed in a cart having stainless steel pipes fixed on it, that is able to move linearly along the horizontal arm element - radial axis - through linear ball bearing guides. The cart is powered by a third motor via a closed-loop roller chain connection. As a result of an integrated control established between the rotation mechanism, the lifting mechanism and cart, the printing unit is able to print a layer in the XY plane by rotating and moving radially according to the 3D construction model. When the layer is finished, the cart can be moved vertically along z-axis to begin printing another layer on top. In an alternative embodiment of the invention, the printing unit comprises a nozzle for extruding a printing material and a printing material delivery module. The printing material delivery module is comprised by a container, for storing printing material, and by a pump for delivery printing material, through at least one pipe, to the nozzle. Yet in another embodiment, the pipe contains an inside helical conveyor adapted to deliver printing material from an inlet to a nozzle outlet in a predefined amount. Said amount is proportional to the speed of the helical conveyor which is controlled by a fourth motor. Yet in another embodiment, the pipe further comprises inside fixed frames, through the path of the printing material to the outlet, to eliminate air bubbles as the printing material pass through them. Yet in another embodiment of the invention, the nozzle can be of different shapes and sizes.

The control module, according to the preferred embodiment, comprises a processor unit and a communication unit. The communication unit is adapted to provide a wireless bidirectional communication link with a remote device for transmitting monitoring data and for receiving operative commands programmed to actuate the motor of the rotation mechanism, the motor of the lifting mechanism, the motor of the printing unit responsible for the radial displacement of the nozzle and the motor of the printing unit responsible for configuring the speed of the helical conveyor. The processor unit comprises processing means configured to operate the rotation mechanism, the lifting mechanism and the printing unit by actuating on the first, second and third motor respectively, according to operative commands received by the communication unit. In one embodiment of the invention, the operative commands received by the communication unit can be a 3D construction model defined in the cartesian coordinate system. In this embodiment, processing mans of the processing unit are configured to convert cartesian coordinates (x, y, z) to polar coordinates (r, Q, z) in which r represents the radius, Q represents the angular displacement and z represents the height. The processing means of the processing unit are then further configured to translate polar coordinates in machine instructions adapted to program the operation of the motor of the rotation mechanism, the motor of the lifting mechanism and the motor of the printing unit responsible for the radial displacement of the nozzle. Yet in another alternative embodiment of the invention, the operative commands received by the communication unit can be operative instructions, programmed to remotely operate the movement of the cart and the printing unit's nozzle operation.

Yet in another alternative embodiment of the invention, the system further comprises a sensorial module, including a set of sensors programmed for monitoring the position of the horizontal arm element, the nozzle, and the amount of printing material extruded by the nozzle.

As will be clear to one skilled in the art, the present invention should not be limited to the embodiments described herein, and a number of changes are possible which remain within the scope of the present invention.

Of course, the preferred embodiments shown above are combinable, in the different possible forms, being herein avoided the repetition all such combinations.

DESCRIPTION OF FIGURES Figure 1 - representation of an embodiment of the automated building system developed, wherein the reference signs represent:

1 - crane structure

2 - horizontal arm element; 3 -vertical mast;

4 - base;

5 - printing unit;

6 - counterweight;

7 - extension mast.

Figure 2 - representation of an embodiment of the connection unit's rotation mechanism, wherein the reference signs represent:

3 - vertical mast;

8 - slewing unit; 9 -first motor;

10 - slewing unit.

Figure 3 - representation of an embodiment of the connection unit's lifting mechanism, wherein the reference signs represent: 3 -vertical mast;

8 - slewing unit;

11 - counterweigh;

12 - roller chain.

Claims

1. Automated building system comprising: a crane structure (1) formed by a horizontal arm element (2) and by a vertical mast (3) that is fixed to a ground by means of a base (4); a connection unit arranged to connect the horizontal arm (2) and the vertical mast (3); a printing unit (5); a control module; characterized in that,

— the connection unit comprises:

— a rotation mechanism comprising a slewing unit (8) installed in the vertical mast (3); said unit (8) connects to the horizontal arm element (2) and is comprised by at least two slewing bearings for providing rotation of the horizontal arm element (2) around the slewing unit (8); said rotation mechanism being driven by a first motor (9);

— a lifting mechanism comprising a linear ball bearing guide installed in the vertical mast (3) and configured to provide a vertical displacement along the vertical axis to the slewing unit (8) and to the horizontal arm element (2) connected to it; said vertical displacement being driven by a second motor;

— the printing unit (5) is installed in the horizontal arm element (2) and is configured to move along said arm element (2) through a closed-loop roller chain powered by a third motor; and

— the control module comprises a processor unit and a communication unit, wherein the processor unit is configured to operate the rotation mechanism, the lifting mechanism and the printing unit (5), actuating on the first, second and third motor respectively, according to operative commands received by the communication unit.

2. Automated building system according to claim 1, wherein the base (4) is a structure formed by four I-beams.

3. Automated building system according to claims 1 or 2, further comprising an extension arm (7) installed between the base (4) and an end of the vertical mast (3).

4. Automated building system according to any of the previous claims, wherein the printing unit (5) comprises a nozzle for extruding a printing material and a printing material delivery module; said module being comprised by:

- a container, for storing printing material;

- a pump for delivery printing material, through at least one pipe, to the nozzle.

5. Automated building system according to claim 4, wherein the pipe contains an inside helical conveyor adapted to deliver printing material from an inlet to a nozzle outlet in a predefined amount; said amount being proportional to the speed of the helical conveyor which is controlled by a fourth motor.

6. Automated building system according to previous claims 4 or 5, wherein the pipe further comprises inside fixed frames in the path of the printing material.

7. Automated building system according to any of the previous claims 4 to 6, wherein the nozzle is of different shapes and sizes.

8. Automated building system according to any of the previous claims, wherein the first motor (9) powers the rotation mechanism by means of a pinion and gear mechanism, and wherein, the slewing bear of the slewing unit works as a spur gear; and a pinion and gear mesh is assembled in the horizontal arm (2).

9. Automated building system according to any of the previous claims, wherein the slewing unit (8) further comprises at least two slip rings and an electric circuit adapted to feed said slip rings.

10. Automated building system according to claim 9, wherein the horizontal arm element (2) comprises coal brushes for connecting the slip rings of the slewing unit (8) to the control module.

11. Automated building system according to any of the previous claims, wherein the horizontal arm (2) further comprises a counterweight (6) installed in an end opposite to a section of the horizontal element (2) where the printing unit (5) moves.

12. Automated building system according to any of the previous claims, wherein the vertical mast (3) is hollow.

13. Automated building system according to claim 12 wherein the lifting mechanism comprises a counterweight (10) connected to the slewing unit (8); said counterweight (10) moving along the vertical axis in function of the vertical displacement of the horizontal arm element (2), by means of a roller chain (11) installed inside of the vertical mask.

14. Automated building system according to any of the previous claims, wherein the processing unit comprises processing means configured to convert cartesian coordinates (x, y, z) to polar coordinates (r, Q, z) in which:

- r, represents the radius;

- Q, represents the angular displacement;

- z, represents the height.

15. Automated building system according to claim 14, wherein the processing means of the processing unit are further configured to translate polar coordinates in machine instructions adapted to program the operation of:

- The motor of the rotation mechanism;

- The motor of the lifting mechanism;

- The motor of the printing unit (5) responsible for the radial displacement of the nozzle.

16. Automated building system according to any of the previous claims further comprising a sensorial module including a set of sensors programmed for monitoring:

- the position of the horizontal arm element (2) and the nozzle; and

- the amount of printing material extruded by the nozzle; and wherein the communication unit is adapted to provide a bidirectional communication link with a remote device for transmitting monitoring data and for receiving operative commands programmed to actuate:

- the motor (9) of the rotation mechanism;

- the motor of the lifting mechanism;

- the motor of the printing unit (5) responsible for the radial displacement of the nozzle;

- the motor of the printing unit (5) responsible for configuring the speed of the helical conveyor.