US20200064817A1 - Automated construction robot systems and methods - Google Patents

Automated construction robot systems and methods Download PDF

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Publication number
US20200064817A1
US20200064817A1 US16/552,875 US201916552875A US2020064817A1 US 20200064817 A1 US20200064817 A1 US 20200064817A1 US 201916552875 A US201916552875 A US 201916552875A US 2020064817 A1 US2020064817 A1 US 2020064817A1
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Prior art keywords
coating material
duty
variable
cycle
assembly
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Abandoned
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US16/552,875
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English (en)
Inventor
David Askey
Daniel POSFAI
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Ascend Robotics LLC
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Ascend Robotics LLC
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Priority to US16/552,875 priority Critical patent/US20200064817A1/en
Publication of US20200064817A1 publication Critical patent/US20200064817A1/en
Assigned to Ascend Robotics LLC reassignment Ascend Robotics LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: POSFAI, Daniel, ASKEY, DAVID
Abandoned legal-status Critical Current

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    • 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
    • G05B19/00—Program-control systems
    • G05B19/02—Program-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of program data in numerical form
    • G05B19/4155—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of program data in numerical form characterised by program execution, i.e. part program or machine function execution, e.g. selection of a program
    • 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
    • B25J11/0075—Manipulators for painting or coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/16—Program controls
    • B25J9/1656—Program controls characterised by programming, planning systems for manipulators
    • B25J9/1669—Program controls characterised by programming, planning systems for manipulators characterised by special application, e.g. multi-arm co-operation, assembly, grasping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J18/00—Arms
    • B25J18/02—Arms extensible
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J19/00—Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
    • B25J19/02—Sensing devices
    • B25J19/021—Optical sensing devices
    • B25J19/023—Optical sensing devices including video camera means
    • 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
    • B25J9/00—Program-controlled manipulators
    • B25J9/0084—Program-controlled manipulators comprising a plurality of manipulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/16—Program controls
    • B25J9/1612—Program controls characterised by the hand, wrist, grip control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/16—Program controls
    • B25J9/1615—Program controls characterised by special kind of manipulator, e.g. planar, scara, gantry, cantilever, space, closed chain, passive/active joints and tendon driven manipulators
    • B25J9/162—Mobile manipulator, movable base with manipulator arm mounted on it
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/16—Program controls
    • B25J9/1679—Program controls characterised by the tasks executed
    • B25J9/1682—Dual arm manipulator; Coordination of several manipulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/16—Program controls
    • B25J9/1679—Program controls characterised by the tasks executed
    • B25J9/1684—Tracking a line or surface by means of sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/16—Program controls
    • B25J9/1694—Program controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
    • B25J9/1697—Vision controlled systems
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G23/00—Working measures on existing buildings
    • E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
    • B05B13/0431—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with spray heads moved by robots or articulated arms, e.g. for applying liquid or other fluent material to three-dimensional [3D] surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Program-controlled manipulators
    • B25J9/16—Program controls
    • B25J9/1656—Program controls characterised by programming, planning systems for manipulators
    • B25J9/1661—Program controls characterised by programming, planning systems for manipulators characterised by task planning, object-oriented languages
    • 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
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40298—Manipulator on vehicle, wheels, mobile
    • 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
    • G05B2219/45013—Spraying, coating, painting
    • 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
    • G05B2219/45065—Sealing, painting robot
    • 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
    • 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
    • G05B2219/50—Machine tool, machine tool null till machine tool work handling
    • G05B2219/50391—Robot

Definitions

  • This disclosure relates to automated robot systems and, more particularly, to automated robot systems for use within the building trades and the construction industry.
  • the robotics industry is enabling the automation of tedious and/or repetitive tasks. Numerous industries (such as the consumer electronics industry and the automotive industry) make extensive use of robotics. And through the use of robotics, a higher level of worker safety may be realized (as robots may be utilized in dangerous environments). Further, a higher level of predictability may be achieved, as robots may continuously and repeatedly perform that same task with a high level of consistency.
  • a variable-duty-cycle microcontroller is configured for use within an automated construction robot system and includes: an inlet port configured to receive coating material from a coating supply system; an outlet port configured to provide a regulated quantity of coating material to a head assembly; and a coating material regulation system configured to control the passage of the coating material from the inlet port to the outlet port, wherein the coating material regulation system is configured to process a variable-duty-cycle control signal and regulate the quantity of coating material applied to a work surface via the head assembly.
  • the coating supply system may include an internal chamber within the automated construction robot system.
  • the coating supply system may include an external container fluidly-coupled to the automated construction robot system.
  • the coating material regulation system may include one or more valve assemblies configured to selectively fluidly-couple the inlet port and the outlet port.
  • the one or more valve assemblies may be configured to be selectively energized and deenergized based, at least in part, upon the variable-duty-cycle control signal. Selectively energizing and deenergizing the one or more valve assemblies based, at least in part, upon the variable-duty-cycle control signal may enable precise control of the quantity of coating material provided to the outlet port.
  • the coating supply system may be a pressurized coating supply system.
  • the variable duty cycle control signal may be configured to have an increased duty cycle when an increased quantity of coating material is needed at the outlet port.
  • the variable duty cycle control signal may be configured to have a decreased duty cycle when a decreased quantity of coating material is needed at the outlet port.
  • a variable-duty-cycle microcontroller is configured for use within an automated construction robot system and includes: an inlet port configured to receive coating material from a coating supply system; an outlet port configured to provide a regulated quantity of coating material to a head assembly; and a coating material regulation system configured to control the passage of the coating material from the inlet port to the outlet port; wherein: the coating material regulation system is configured to process a variable-duty-cycle control signal and regulate the quantity of coating material applied to a work surface via the head assembly, the coating material regulation system includes one or more valve assemblies configured to selectively fluidly-couple the inlet port and the outlet port, the variable duty cycle control signal is configured to have an increased duty cycle when an increased quantity of coating material is needed at the outlet port, and the variable duty cycle control signal is configured to have a decreased duty cycle when a decreased quantity of coating material is needed at the outlet port.
  • the coating supply system may include an internal chamber within the automated construction robot system.
  • the coating supply system may include an external container fluidly-coupled to the automated construction robot system.
  • the one or more valve assemblies may be configured to be selectively energized and deenergized based, at least in part, upon the variable-duty-cycle control signal. Selectively energizing and deenergizing the one or more valve assemblies based, at least in part, upon the variable-duty-cycle control signal may enable precise control of the quantity of coating material provided to the outlet port.
  • the coating supply system may be a pressurized coating supply system.
  • an automated construction robot system includes: a mobile base assembly configured to be displaceable within a work area; a head assembly configured to process a work surface; an arm assembly configured to moveably-couple the head assembly and the mobile base assembly and controllably-displace the head assembly with respect to the work surface; a variable-duty-cycle microcontroller configured to provide a coating material to the head assembly; and a computational system configured to: manipulate one or more of the mobile base assembly, the head assembly and the arm assembly to apply the coating material to the work surface via the head assembly.
  • the variable-duty-cycle microcontroller may include: an inlet port configured to receive the coating material from a coating supply system; an outlet port configured to provide a regulated quantity of coating material to the head assembly; and a coating material regulation system configured to control the passage of the coating material from the inlet port to the outlet port, wherein the coating material regulation system is configured to process a variable-duty-cycle control signal provided by the computational system and regulate the quantity of coating material applied to the work surface via the head assembly.
  • the coating material regulation system may include one or more valve assemblies configured to selectively fluidly-couple the inlet port and the outlet port.
  • the one or more valve assemblies may be configured to be selectively energized and deenergized based, at least in part, upon the variable-duty-cycle control signal. Selectively energizing and deenergizing the one or more valve assemblies based, at least in part, upon the variable-duty-cycle control signal may enable precise control of the quantity of coating material provided to the outlet port.
  • the variable duty cycle control signal may be configured to have an increased duty cycle when an increased quantity of coating material is needed at the outlet port.
  • the variable duty cycle control signal may be configured to have a decreased duty cycle when a decreased quantity of coating material is needed at the outlet port.
  • FIGS. 1A-1E are diagrammatic views of an automated construction robot system according to an embodiment of the present disclosure
  • FIG. 2 is a flowchart of an automated construction robot process executed by the automated construction robot system of FIGS. 1A-1E according to an embodiment of the present disclosure
  • FIG. 3 is a diagrammatic detail view of the head assembly of FIGS. 1A-1E according to an embodiment of the present disclosure
  • FIG. 4 is a another flowchart of an automated construction robot process executed by the automated construction robot system of FIGS. 1A-1E according to an embodiment of the present disclosure
  • FIG. 5 is a another flowchart of an automated construction robot process executed by the automated construction robot system of FIGS. 1A-1E according to an embodiment of the present disclosure
  • FIG. 6 is a another flowchart of an automated construction robot process executed by the automated construction robot system of FIGS. 1A-1E according to an embodiment of the present disclosure
  • FIG. 7 is a another flowchart of an automated construction robot process executed by the automated construction robot system of FIGS. 1A-1E according to an embodiment of the present disclosure
  • FIG. 8 is a another flowchart of an automated construction robot process executed by the automated construction robot system of FIGS. 1A-1E according to an embodiment of the present disclosure.
  • FIG. 9 is a diagrammatic detail view of a variable-duty-cycle microcontroller assembly of the automated construction robot system of FIGS. 1A-1E according to an embodiment of the present disclosure.
  • automated construction robot system 10 may include mobile base assembly 12 configured to be displaceable within work area 14 .
  • mobile base assembly 12 may include any kind of base assembly that would allow for the movement of automated construction robot system 10 within work area 14 .
  • mobile base assembly 12 may include but is not limited to a mobile base assembly that includes a plurality of wheels that allow for the movement of mobile base assembly 12 within work area 14 , wherein such a wheeled mobile base assembly may be highly suitable for situations in which work area 14 is a smooth surface (e.g., a finished floor).
  • mobile base assembly 12 may include but is not limited to a mobile base assembly that includes a plurality of tracks (not shown) that allow for the movement of mobile base assembly 12 within work area 14 , wherein such a tracked mobile base assembly may be highly suitable for situations in which work area 14 is a rough surface (e.g., uneven ground).
  • Automated construction robot system 10 may include head assembly 16 configured to process work surface 18 .
  • work surface 18 may include but are not limited to interior walls, exterior walls, trim work, door assemblies, and window assemblies.
  • head assembly 16 may be configured to apply a coating material (e.g., a sealer coating, a primer coating, a paint coating, a stain coating, a varnish coating, a polyurethane coating, and an epoxy-based coating) to work surface 18 . Further and as will be discussed below in greater detail, head assembly 16 may be configured to make repairs to work surface 18 .
  • a coating material e.g., a sealer coating, a primer coating, a paint coating, a stain coating, a varnish coating, a polyurethane coating, and an epoxy-based coating
  • Automated construction robot system 10 may include arm assembly 20 configured to moveably-couple head assembly 16 and mobile base assembly 12 and controllably-displace head assembly 16 with respect to work surface 18 .
  • arm assembly 20 may include any hydraulically-actuated, pneumatically-actuated, and/or electrically-actuated, computer-controllable arm assembly that may be configured to movably-couple head assembly 16 and mobile base assembly 12 .
  • Arm assembly 20 may include wrist assembly 22 configured to enable the rotation of head assembly 16 with respect to arm assembly 20 .
  • wrist assembly 22 may include any assembly that allows for the rotation of head assembly 16 about an X-axis, a Y-axis, and/or a Z-axis.
  • Arm assembly 20 may include rotation assembly 24 configured to enable the rotation of arm assembly 20 with respect to mobile base assembly 12 .
  • rotation assembly 24 may include any assembly that allows for the rotation of arm assembly 20 about a Z-axis.
  • Automated construction robot system 10 may include machine vision system 26 configured to scan a target area (e.g., target area 28 ) and generate target area information 30 .
  • machine vision system 26 may include but are not limited to one or more of an RGB imaging system, an infrared imaging system, an ultraviolet imaging system, a laser imaging system, a SONAR imaging system, a RADAR imaging system, and a thermal imaging system.
  • target area information 30 may include but is not limited to any analog and/or digital representation of target area 28 that enables (as will be discussed below in greater detail) automated construction robot system 10 to process target area 28 and control one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • the instruction sets and subroutines of automated construction robot process 34 may be stored on storage device 36 coupled to computational system 32 , may be executed by one or more processors (not shown) and one or more memory architectures (not shown) included within computational system 32 .
  • Examples of storage device 36 may include but are not limited to: a hard disk drive; a RAID device; a random access memory (RAM); a read-only memory (ROM); and all forms of flash memory storage devices.
  • Automated construction robot system 10 may be coupled to network 40 to e.g., allow automated construction robot system 10 to be controlled by user 42 , allow for the receiving of instructions by automated construction robot system 10 , and allow for the providing of data (e.g., status data, progress data, defect data, etc.) to user 42 .
  • automated construction robot system 10 may be configured to be wirelessly coupled to access point 44 via wireless communication channel 46 established between automated construction robot system 10 and access point 44 .
  • Examples of network 40 may include but are not limited to any type of wired or wireless network (e.g., a local area network; a wide area network; a wifi network, a cellular network, the internet and/or an intranet).
  • Examples of access point 44 may include, but are not limited to, an IEEE 802.11a/b/g/n access point, a Wi-Fi access point, and/or a Bluetooth access point that is capable of establishing wireless communication channel 46 between automated construction robot system 10 and access point 44 .
  • IEEE 802.11x specifications may use Ethernet protocol and carrier sense multiple access with collision avoidance (i.e., CSMA/CA) for path sharing.
  • the various 802.11x specifications may use phase-shift keying (i.e., PSK) modulation or complementary code keying (i.e., CCK) modulation, for example.
  • PSK phase-shift keying
  • CCK complementary code keying
  • Bluetooth is a telecommunications industry specification that allows e.g., mobile phones, computers, and personal digital assistants to be interconnected using a short-range wireless connection.
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot process 34 may be configured to manipulate 100 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 (e.g., a sealer coating, a primer coating, a paint coating, a stain coating, a varnish coating, a polyurethane coating, and an epoxy-based coating) to work surface 18 via head assembly 16 .
  • coating material 48 e.g., a sealer coating, a primer coating, a paint coating, a stain coating, a varnish coating, a polyurethane coating, and an epoxy-based coating
  • Coating material 48 may be locally or remotely provided.
  • automated construction robot system 10 may include an internal chamber (e.g., internal chamber 50 ) within which coating material 48 may be stored.
  • internal chamber 50 may be configured so that user 42 of automated construction robot system 10 may fill internal chamber 50 with coating material 48 from e.g., a supply bucket/container.
  • automated construction robot system 10 may be configured to receive coating material 48 from an external container.
  • supply line assembly 52 may be configured to be coupled to external container 54 (that may contain coating material 48 ).
  • Additional external containers e.g., flushing fluid supply container 56 and flushing fluid receipt container 58
  • supply line assembly 52 may be placed into flushing fluid supply container 56 and head assembly 16 may be positioned to discharge into flushing fluid receipt container 58 ).
  • automated construction robot process 34 When manipulating 100 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 to work surface 18 via head assembly 16 , automated construction robot process 34 perform one or more of the following operations:
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot system 10 may include machine vision system 26 configured to scan a target area (e.g., target area 28 ) and generate target area information 30 .
  • automated construction robot process 34 may manipulate and maneuver automated construction robot system 10 (generally) and mobile base assembly 12 (specifically) so that machine vision system 26 may scan the entirety of work surface 18 to generate target area information 30 .
  • automated construction robot process 34 may be configured to process 200 target area information 30 to define work area coating plan 60 .
  • work surface 18 is a room that includes four walls, two doors, two windows, six electrical outlets and two light switches. Accordingly, automated construction robot process 34 may process 200 target area information 30 to locate such walls, doors, windows, electrical outlets and light switches within work surface 18 and define work area coating plan 60 .
  • automated construction robot process 34 may generate 202 one or more coating plan instructions (e.g., coating plan instructions 62 ) based, at least in part, upon work area coating plan 60 .
  • coating plan instructions 62 may instruct the various portions of automated construction robot system 10 (e.g., mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 ) to apply coating material 48 to whatever portions of work surface 18 need to be coated (e.g. bare drywall) while bot applying coating material 48 to whatever portions of work surface 18 should not be coated (e.g. doors, windows, electrical outlets, light switches).
  • the coating plan instructions (e.g., coating plan instructions 62 ) generated 202 may instruct the various portions of automated construction robot system 10 (e.g., mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 ) to e.g., applying coating material 48 from the floor to a height of 10 ′ for the first 23 ′ of the first wall . . . and then apply coating material 48 from 8 ′ to 10 ′ for the next 4 ′ of the first wall . . . and then apply coating material 48 from the floor to a height of 10 ′ for the remaining 23 ′ of the first wall.
  • automated construction robot system 10 e.g., mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26
  • coating material 48 from the floor to a height of 10 ′ for the first 23 ′ of the first wall . . .
  • coating material 48 from 8 ′ to 10 ′ for the next
  • automated construction robot process 34 may manipulate 204 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 to work surface 18 via head assembly 12 based, at least in part, upon one or more the coating plan instructions (e.g., coating plan instructions 62 ).
  • coating plan instructions e.g., coating plan instructions 62
  • head assembly 12 applies coating material 48 in e.g., a 12 ′′ wide stripe.
  • automated construction robot process 34 may manipulate 204 the various portions of automated construction robot system 10 (e.g., mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 ) to apply twenty-three 12 ′′ wide vertical stripes of coating material 48 from floor level to 10 ′ high . . . and then apply four 12 ′′ wide vertical stripes of coating material 48 from 8 ′ feet high to 10 ′ feet high . . . and then apply twenty-three 12 ′′ wide vertical stripes of coating material 48 from floor level to 10 ′ high.
  • automated construction robot process 34 may overlap these stripes of coating material 48 to ensure consistent coverage.
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot system 10 may include machine vision system 26 configured to scan a target area (e.g., target area 28 ) and generate target area information 30 .
  • automated construction robot process 34 may manipulate and maneuver automated construction robot system 10 (generally) and mobile base assembly 12 (specifically) so that machine vision system 26 may scan the entirety of work surface 18 to generate target area information 30 .
  • automated construction robot process 34 may be configured to process 250 target area information 30 to identify any surface defects (e.g., surface defect 64 ).
  • surface defects e.g., surface defect 64
  • the seams and interior corners are covered with a combination of joint tape and drywall compound.
  • the fasteners that attach the drywall to the underlying studs are fastened via drywall screws and/or drywall nails, wherein the heads of such fasteners are also covered with drywall compound.
  • exterior corners are covered with corner bead that is fastened with either drywall screws or drywall nails, wherein this corner bead and these fasteners are covered with drywall compound.
  • surface defects are routinely missed and need to be addressed prior to the application of coating material 48 .
  • Evidence of such surface defects may be memorialized (e.g., via stored images and/or videos) to document such surface defects and provide evidence of the same for reimbursement purposes from third parties (e.g., the drywall installers).
  • Examples of such surface defects may include but are not limited to one or more of:
  • automated construction robot process 34 may generate 252 one or more remedial instructions (e.g., remedial instructions 66 ) based, at least in part, upon the surface defect (e.g., surface defect 64 ) identified. As would be expected, these remedial instructions (e.g., remedial instructions 66 ) may vary depending upon the type of surface defect (e.g., surface defect 64 ) identified.
  • automated construction robot process 34 may manipulate 254 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 based, at least in part, upon the one or more remedial instructions (e.g., remedial instructions 66 ).
  • remedial instructions 66 may instruct the various portions of automated construction robot system 10 (e.g., mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 ) to perform the above-described remedial actions.
  • manipulating 254 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 based, at least in part, upon the one or more remedial instructions (e.g., remedial instructions 66 ) may include one or more of:
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot process 34 may manipulate and maneuver automated construction robot system 10 (generally) and mobile base assembly 12 (specifically) so that machine vision system 26 may scan the entirety of work surface 18 to generate target area information 30 . Additionally and as discussed above, automated construction robot process 34 may manipulate 100 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 to work surface 18 via head assembly 16 . Further and as discussed above, automated construction robot process 34 may manipulate 204 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 to work surface 18 via head assembly 12 based, at least in part, upon one or more the coating plan instructions (e.g., coating plan instructions 62 ).
  • the coating plan instructions e.g., coating plan instructions 62
  • automated construction robot process 34 may manipulate 254 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 based, at least in part, upon the one or more remedial instructions (e.g., remedial instructions 66 ). Accordingly, it is foreseeable that one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 may make contact with (or impact) another object, examples of which may include but are not limited to a worker, a wall, and a piece of furniture.
  • automated construction robot process 34 when automated construction robot process 34 is manipulating 300 (for any of the reasons discussed above) one or more of mobile base assembly 12 , head assembly 66 and arm assembly 22 , if contact of mobile base assembly 12 , head assembly 16 and/or arm assembly 22 with an object (e.g., user 42 ) is detected 302 , automated construction robot process 34 may adjust 304 the manipulation of mobile base assembly 12 , head assembly 16 and/or arm assembly 22 in response to sensing such contact with the object (e.g., user 42 ).
  • object e.g., user 42
  • arm assembly 20 may include any hydraulically-actuated, pneumatically-actuated, and/or electrically-actuated computer-controllable arm assembly that may be configured to movably-couple head assembly 16 and mobile base assembly 12 .
  • automated construction robot process 34 may be configured to monitor the hydraulic and/or pneumatic pressures within arm assembly 20 (to detect 302 such a contact event). If electrically actuated, automated construction robot process 34 may be configured to monitor the electrical current within arm assembly 20 (to detect 302 such a contact event).
  • touch sensitive bumper assemblies e.g., bumper assembly 68
  • base assembly 12 may be included within base assembly 12 and configured to detect 302 such a contact event.
  • automated construction robot process 34 may effectuate one or more of the following operations:
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot system 10 may include machine vision system 26 configured to scan a target area (e.g., target area 28 ) and generate target area information 30 .
  • automated construction robot process 34 may manipulate and maneuver automated construction robot system 10 (generally) and mobile base assembly 12 (specifically) so that machine vision system 26 may scan the entirety of work surface 18 to generate target area information 30 .
  • work surface 18 is a room that includes four walls, two doors, two windows, six electrical outlets and two light switches.
  • automated construction robot process 34 may be configured to manipulate 100 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 to work surface 18 via head assembly 16 .
  • automated construction robot process 34 may process 200 target area information 30 to locate e.g., walls, doors, windows, electrical outlets and light switches within work surface 18 .
  • automated construction robot process 34 may process 350 target area information 30 to generate one or more edge instructions (e.g., edge instructions 70 ).
  • automated construction robot system 10 may effectuate the following operations:
  • Automated construction robot process 34 may manipulate 356 the angle of incidence of head assembly 16 with respect to work surface 18 based, at least in part, upon the one or more edge instructions (e.g., edge instructions 70 ).
  • the angle of incidence ( ⁇ ) is the angle between a ray incident on a surface (e.g., work surface 18 ) and the line perpendicular to the surface at the point of incidence. Accordingly and when spray fan 150 is positioned perpendicular to work surface 18 (as shown in solid lines), the angle of incidence ( ⁇ ) is 90 degrees.
  • edges 152 , 154 of coating material 48 may result in a decrease in the crispness of edges 152 , 154 of coating material 48 applied to work surface 18 (thus allowing for the dithering of edges 152 , 154 and a blending of the stripes of coating material 48 ).
  • rotating spray fan 150 about pivot point 156 included within wrist assembly 22 in a clockwise/counterclockwise direction may result in a decrease in the angle of incidence ( ⁇ ) and an increase in the crispness of: the edge 152 (when rotating in a clockwise direction) and edge 154 (when rotating in a counterclockwise direction); thus allowing for coating material 48 to be “cut in” around e.g., ceilings, floors, walls, doors, windows, switches, outlets, baseboard moldings, crown moldings, etc.
  • automated construction robot process 34 effectuate one or more of the following operations:
  • automated construction robot process 34 may effectuate one or more of the following operations:
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot system 10 may include machine vision system 26 configured to scan a target area (e.g., target area 28 ) and generate target area information 30 .
  • automated construction robot process 34 may manipulate and maneuver automated construction robot system 10 (generally) and mobile base assembly 12 (specifically) so that machine vision system 26 may scan the entirety of work surface 18 to generate target area information 30 .
  • machine vision system 26 may be configured to scan a non-target area (e.g., non-target area 72 and/or non-target area 74 ) and generate non-target area information 76 .
  • These non-target areas (e.g., non-target area 72 and/or non-target area 74 ) may be positioned proximate target area 28 .
  • non-target area 72 may be positioned on the left of target area 28 and/or non-target area 74 may be positioned on the right of target area 28 . Accordingly and assuming that coating material 48 is applied in a left-to-right fashion, non-target area 72 may be the area to which coating material 48 has already been applied and non-target area 74 may be the area to which coating material 48 has not yet been applied.
  • automated construction robot process 34 may be configured to manipulate 100 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 to work surface 18 via head assembly 16 . Additionally, automated construction robot process 34 may be configured to process 400 the non-target area information (e.g., non-target area information 76 ) to generate one or more remedial instructions (e.g., remedial instructions 66 ).
  • non-target area information e.g., non-target area information 76
  • remedial instructions e.g., remedial instructions 66
  • automated construction robot process 34 may manipulate 402 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 based, at least in part, upon the one or more remedial instructions (e.g., remedial instructions 66 ).
  • remedial instructions 66 may instruct the various portions of automated construction robot system 10 (e.g., mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 ) to perform various remedial actions (as will be discussed below in greater detail).
  • non-target area 72 may include an area (within work surface 18 ) to which coating material 48 has already been applied, wherein processing 400 non-target area information 76 to generate one or more remedial instructions (e.g., remedial instructions 66 ) includes processing 404 non-target area information 76 to identify an applied coating material defect (e.g., coating defect 80 ) within non-target area 72 .
  • processing 400 non-target area information 76 to generate one or more remedial instructions includes processing 404 non-target area information 76 to identify an applied coating material defect (e.g., coating defect 80 ) within non-target area 72 .
  • Examples of such applied coating material defects may include but are not limited to one or more of:
  • automated construction robot process 34 may manipulate 406 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 to address the identified applied coating material defect (e.g., coating defect 80 ).
  • Examples of the manner in which automated construction robot process 34 may manipulate 406 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 to address the identified applied coating material defect (e.g., coating defect 80 ) may include but are not limited to:.
  • non-target area 74 may include an area (within work area 18 ) to which coating material 48 has not yet been applied, wherein processing 400 non-target area information 76 to generate one or more remedial instructions (e.g., remedial instructions 66 ) may include processing 408 non-target area information 76 to identify a surface defect (e.g., surface defect 64 ) within non-target area 74 .
  • processing 400 non-target area information 76 to generate one or more remedial instructions may include processing 408 non-target area information 76 to identify a surface defect (e.g., surface defect 64 ) within non-target area 74 .
  • examples of such surface defects may include but are not limited to one or more of:
  • automated construction robot process 34 may manipulate 410 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 to address the identified surface defect (e.g., surface defect 64 ).
  • Examples of the manner in which automated construction robot process 34 may manipulate 410 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 22 to address the identified surface defect (e.g., surface defect 64 ) may include but are not limited to:
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 . Further and as discussed above, automated construction robot process 34 may be configured to manipulate 100 one or more of mobile base assembly 12 , head assembly 16 and arm assembly 20 to apply coating material 48 to work surface 18 via head assembly 16 .
  • supply line assembly 52 may be utilized to receive coating material 48 from a coating supply system (e.g., internal chamber 50 or external container 54 ).
  • Pump assembly 162 may be utilized to pressurize coating material 48 (drawn from internal chamber 50 /external container 54 ) and variable-duty-cycle microcontroller assembly 164 may be utilized to control 116 the volume of coating material 48 and/or control 118 the pressure of coating material 48 provided to head assembly 16 .
  • Variable-duty-cycle microcontroller 164 may include:
  • Coating material regulation system 454 may include one or more valve assemblies (e.g., valve assemblies 458 ) configured to selectively fluidly-couple inlet port 450 and outlet port 452 .
  • the one or more valve assemblies e.g., valve assemblies 458
  • the one or more valve assemblies may be configured to be selectively energized and deenergized based, at least in part, upon the variable-duty-cycle control signal (e.g., control signal 456 ).
  • control signal 456 e.g., control signal 456
  • automated construction robot process 34 may be configured to monitor the pressure of coating material 48 being applied to head assembly 16 .
  • variable-duty-cycle control signal (e.g., control signal 456 ) may be adjusted to regulate the pressure of the coating material 48 being applied to head assembly 16 downward.
  • the variable duty cycle control signal (e.g., control signal 456 ) may be adjusted to have a decreased duty cycle (e.g., control signal 506 B) when a decreased quantity of coating material 48 is needed at outlet port 452 .
  • variable-duty-cycle control signal e.g., control signal 456
  • the variable duty cycle control signal may be adjusted to have an increased duty cycle (e.g., control signal 456 A) when an increased quantity of coating material 48 is needed at outlet port 504 .
  • selectively energizing and deenergizing the one or more valve assemblies based, at least in part, upon the variable-duty-cycle control signal (e.g., control signal 456 ) may enable precise control of the quantity of coating material 48 provided to outlet port 452 .
  • automated construction robot system 10 may include computational system 32 configured to execute automated construction robot process 34 and enable the interfacing with (and controlling of) one or more of mobile base assembly 12 , head assembly 16 , arm assembly 20 , wrist assembly 22 , rotation assembly 24 and machine vision system 26 .
  • automated construction robot system 10 may include machine vision system 26 configured to scan a target area (e.g., target area 28 ) and generate target area information 30 . Additionally, machine vision system 26 may be configured to scan a non-target area (e.g., non-target area 72 and/or non-target area 74 ) and generate non-target area information 76 .
  • a target area e.g., target area 28
  • machine vision system 26 may be configured to scan a non-target area (e.g., non-target area 72 and/or non-target area 74 ) and generate non-target area information 76 .
  • automated construction robot system 10 may include a plurality of automated construction robots, namely a primary construction robot (e.g., automated construction robot system 10 ); and a scout construction robot (e.g., scanning robot system 80 ).
  • a primary construction robot e.g., automated construction robot system 10
  • a scout construction robot e.g., scanning robot system 80
  • the scout construction robot (e.g., scanning robot system 80 ) may be configured to effectuate the above-described scanning functionality (e.g., the scanning of target area 28 and/or non-target area 72 , 74 ) to generate target area information 30 and/or non-target area information 76 .
  • scanning robot system 80 may be configured to effectuate the above-described scanning functionality (e.g., the scanning of target area 28 and/or non-target area 72 , 74 ) to generate target area information 30 and/or non-target area information 76 .
  • automated construction robot system 10 may be configured to be wirelessly coupled to access point 44 via wireless communication channel 46 established between automated construction robot system 10 and access point 44 .
  • scout construction robot e.g., scanning robot system 80
  • network 40 and access point 44 may be configured to allow automated construction robot system 10 and scanning robot system 80 to communicate, thus enabling the above-described scanning operations.
  • the present disclosure may be embodied as a method, a system, or a computer program product. Accordingly, the present disclosure may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present disclosure may take the form of a computer program product on a computer-usable storage medium having computer-usable program code embodied in the medium.
  • the computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium may include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a transmission media such as those supporting the Internet or an intranet, or a magnetic storage device.
  • the computer-usable or computer-readable medium may also be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory.
  • a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
  • the computer-usable medium may include a propagated data signal with the computer-usable program code embodied therewith, either in baseband or as part of a carrier wave.
  • the computer usable program code may be transmitted using any appropriate medium, including but not limited to the Internet, wireline, optical fiber cable, RF, etc.
  • Computer program code for carrying out operations of the present disclosure may be written in an object oriented programming language such as Java, Smalltalk, C++ or the like. However, the computer program code for carrying out operations of the present disclosure may also be written in conventional procedural programming languages, such as the “C” programming language or similar programming languages.
  • the program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through a local area network/a wide area network/the Internet (e.g., network 14 ).
  • These computer program instructions may also be stored in a computer-readable memory that may direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
  • the computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
  • each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s).
  • the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

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