A modular system and method for the making and/or prototype production of self-configuring systems

Technical field

This invention relates to a modular system for the making and/or prototype production of self-configuring systems and a method for making and/or prototype production of self-configuring systems.

Background art

In the field of automation and robotics there are various solutions for the making and/or prototype production of mobile robotic platforms and automatic stations.

The above-mentioned solutions comprise the use of mechanical, electronic or mechatronic structures capable of making ad hoc systems to perform specific technical functions or applications.

In particular, the above-mentioned solutions comprise the use of predetermined structures to which is associated a mathematical model which describes its shape, dimensions and position in space. In addition, the mathematical model identifies the position and the orientation of the sensors and actuators installed on the structures.

The mathematical model for describing the physical structure of the robot (or other automated system) is necessary in order to provide a software for navigation and control of the robot.

Currently, the majority of robots (or other automatic/automated systems) have a mechanical structure pre-set and every modification requires designers to make complex modifications to the control algorithms (such as, for example, navigation algorithms, movement algorithms or the implementation of safety procedures).

Disadvantageously, any modification to the structure of the robot requires a re-writing or an updating of the management and control software in order to adapt the mathematical model (otherwise the robot would not be able to move and operate in a manner in line with the new structure). Moreover, the majority of robots are made starting from subsystems specifically designed for that type of product or application and, once the life cycle of the structure has been completed, the hardware cannot be re used for other applications.

Modular robots are also known which are able to join functionally separate and pre-constructed modules: the modularity of this type of robot is in terms of hardware but not software. Once the robotic system has been assembled, it is in fact necessary to make the model to enable the control of the robot. It also has the drawback of being unable to re-use the hardware for other purposes at the end of the life cycle of the structure. Disadvantageously, the solutions described above require complex computer hardware in order to obtain all the information necessary for obtaining the mathematical model necessary for controlling the robot.

Disadvantageously, the solutions described above have specific geometries and difficult to be modelled on the basis of the function to be performed and the elements to be combined with each other.

Disclosure of the invention

The technical purpose of this invention is therefore to provide a modular system and a method for making and/or prototype production of self configuring systems which is able to overcome the drawbacks of the prior art.

An aim of this invention is therefore to provide a modular system and a method for making and/or prototype production of self-configuring systems, which can be used in several applications or various products. Another aim of this invention is to provide a modular system for the making and/or prototype production of self-configuring systems which allow a mathematical model to be obtained extremely easily as a function of the various products or applications.

The technical purpose and aims specified are substantially achieved by means of a modular system and a method for making and/or prototype production of self-configuring systems comprising the technical features described in one or more of the appended claims.

In particular, the technical purpose and aims specified are achieved by a modular system for the making and/or prototype production of self configuring systems, comprising at least one module comprising a structural element defined by a main body extending longitudinally along a respective axis of extension, at least one sensor designed to measure spatial information of the structural element, at least one transmitter designed to transmit the spatial information measured and an identification code of the structural element. The modular system also comprises a modelling unit designed to receive the spatial information and the identification code transmitted by the transmitter and to process it as a function of a preset reference system.

Advantageously, the modular system makes it possible to obtain a model of the structure extremely easily so as to avoid complicated calculations even in the case of modifications to the structure.

In particular, the technical purpose and aims specified are achieved by a method for making and/or prototype production of self-configuring systems, comprising the steps of:

- preparing at least one module comprising a structural element defined by a main body extending longitudinally along a respective axis of extension, at least one sensor and at least one transmitter;

- preparing a modelling unit;

- measuring, using the at least one sensor, spatial information of the structural element;

- transmitting, by means of the at least one transmitter, the spatial information of the at least one sensor and an identification code of the structural element to the modelling unit;

- processing, using the modelling unit, the spatial information and the identification code transmitted from the at least one transmitter as a function of a preset reference system.

Further features and advantages of the invention are more apparent in the non-limiting description which follows of a modular system and a method for making and/or prototype production of self-configuring systems.

Brief description of the drawings

The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without restricting the scope of the invention and in which:

- Figure 1 is a schematic view of a modular system according to the invention.

Detailed description of preferred embodiments of the invention

With reference to the accompanying drawings, the numeral 1 identifies a modular system for the making and/or prototype production of self configuring systems which, for simplicity of description, will be referred to as a modular system 1.

The modular system 1 comprises at least one module 2 comprising a structural element 3 defined by a main body 3a. The main body 3a has a longitudinal shape extending along a respective axis of extension“X”.

The main body 3a can have different dimensions depending on the use and/or needs of the user who will install the modular system.

For example, the main body 3a has a length“L” of between 200 and 2000 mm, a height“H” of between 50 mm and 150 mm and a thickness of between 40 and 150 mm. The length“L” is the dimension along which the main body 3 extends.

These dimensions are only indicative and the main body 3, depending on the use or the system to be made, can have other dimensions.

Preferably, the main body 3a comprises connectors 3b designed to connect the main body 3a to other main bodies 3a or to other elements if necessary.

The module 2 comprises at least one sensor designed to measure spatial information of the structural element 3.

Spatial information relates to information on the structural element 3 which comprises an orientation and/or a position and/or a dimension of the structural element 3.

This spatial information is measured relative to a preset reference system so that it can take into account the correct orientation of the structural element 3.

The module 2 also comprises at least one transmitter 4 designed to transmit the spatial information measured by means of the sensor and an identification code of the structural element 3.

Preferably, the transmitter 4 can transmit the spatial information and the identification code by cable 4a.

For example, the transmitter 4 is able to transmit the information and the identification code by cable 4a through serial ports, I2C (Inter Integrated Circuit), USB (Universal Serial Bus), CAN BUS (Controller Area Network Bus) or POE (Power Over Ethernet) and/or the like.

Preferably, the transmitter 4 can transmit the spatial information and the identification code in a wireless 4b fashion.

For example, the transmitter 4 is able to transmit the information via wireless 4b using Bluetooth, ZigBee, Wi-Fi, NFC (Near Field Communication), RFID (Radio-Frequency Identification), UWB (Ultra Wide Band) and/or the like.

Preferably, the transmitter 4 can be made either by cable 4a or via wireless 4b with a combination of one or more of the examples described above.

The modular system 1 also comprises a modelling unit 5 designed to receive the spatial information and the identification code transmitted by the transmitter 4 and to process it as a function of the above-mentioned preset reference system. In other words, the modelling unit 5 is able to process graphically and/or in the form of formulas and/or diagrams the model of the modular system 2 used for making the automated device (such as, without limiting the invention, robots or automated stations). In other words, the modelling unit 5 is able to reconstruct on the basis of the spatial information the shape and the overall dimensions of the mechatronic system constructed.

Preferably, the modelling unit 5 is able to transmit the spatial information and the identification code to a user interface and/or a control system. In other words, the modelling unit 5 performs the modelling task which would normally require hours of calculations and programming, thus allowing an immediate control of the modular system 1 once assembled.

Preferably, the modelling unit 5 can be a device installed in the proximity of the at least one module 2.

Preferably, the modelling unit 5 can be a software installed on a device with which a user can interact (such as, for example, a computer which is equipped with an interface for controlling the modular system 1 ).

In other words, the modelling unit 5 can be a dedicated device or a software module implemented on a microprocessor or on a PC.

Preferably, the modular system 1 can comprise a power supply system designed to power the at least one sensor and/or the at least one transmitter 4 and/or the modelling unit 5.

This supply system may be made by means of wired connection or by using forms of “energy harvesting” (the process by which it is possible to capture and save the forms of alternative energy such as, for example, power transmission by radio wave).

According to a first embodiment of the modular system 1 , the at least one sensor can be an accelerometer or a gyroscope (or an inertial sensor comprising both the accelerometer and the gyroscope) designed to measure the spatial information along at least a spatial coordinate of the structural element 3. In other words, taking as reference the structural element 3, the sensor may measure a spatial information along the axis of extension “X” and/or along the axis along which the height“H” of the structural element 3 extends (perpendicular to the axis of extension“X”) and/or along the axis along which the thickness of the structural element 3 extends (perpendicular to both the axis of extension“X” and the one along which the height“H” extends). If the sensor is an accelerometer and/or a gyroscope, it can be a single- axial or tri-axial measurement sensor. The modelling unit 5 is therefore able to identify an orientation of the structural element 3 as a function of the spatial coordinate measured as described above.

According to a further embodiment of the modular system 1 , the at least one sensor is at least a magnetometer and the modelling unit 5 is able to identify an orientation of the structural element 3. Preferably, if the module 2 comprises at least three magnetometers, the modelling unit 5 is able to identify an orientation of the structural element 3 relative to the terrestrial magnetic north.

This embodiment allows an absolute orientation of the structural element 3 to be identified (using terrestrial magnetic north as a preset reference the system).

According to a further embodiment of the modular system 1 , the at least one sensor is made by means of at least two radio modules and the modelling unit 5 is able to identify an orientation of the structural element 3 by radio-localisation.

When the communication between the modules 2 and the modelling unit 5 occurs by at least one radio system (the radio modules), then this radio system must allow its localisation in space, relative to a radio localisation system present in the modelling unit.

The radio-localisation can be performed with Ultra Wide Band (UWB), Radio Frequency Identification (RFID) or similar systems.

The radio-localisation can be performed using the typical methods of this scientific discipline, including, for example, calculation of the flight time.

The radios integrated in the module according to the invention will communicate with the central measurement unit, allowing identification of their relative spatial position and, if necessary, the simultaneous data exchange relating to their orientation in space if obtained from or inferred by mathematical calculations on inertial sensors (accelerometers, gyroscopes and/or magnetometers). In this case, the modelling unit 5 receives the information coming from each element, containing the identifier, the position (that is, the relative position measured with radio-localisation systems), the orientation (relative or absolute with respect to the magnetic north) and the length of each of them.

This information can be sent by the modules or requested when necessary by the modelling unit 5. After the collection of the information, the modelling unit 5 reconstructs the shape and dimensions of the mechatronic system constructed.

It should be noted that the above-mentioned embodiments can be used in combination, thus resulting in a more precise measurement and therefore obtaining more precise spatial information for the modelling by the modelling unit 5.

A further embodiment of the modular system 1 (not illustrated) comprises the connection of more than one module 2 to the modelling unit 5. A further embodiment of the modular system 1 (not illustrated) comprises a plurality of modules 2 interconnected in succession as a function of the mechatronic system to be made.

Alternatively, the modular system 1 is made by means of groups of modules 2 connected directly to the modelling unit 5 and in which each group of modules 2 comprises a plurality of modules 2 interconnected in succession.

Those described above are only some of the possible embodiments which can be customised according to the aim of the system to be made.

According to the embodiment comprising a plurality of modules 2 interconnected in succession, the modules 2 are connected to each other by means of the connectors 3b of the main body 3a of the structural element 3.

It follows that it is therefore possible to use structural elements 3 of different lengths (but also thicknesses and/or heights) in such a way as to obtain the desired system. In this embodiment, each transmitter 4 is designed to transmit the spatial information and the identification code to an adjacent transmitter and/or to the modelling unit 5.

For example, with a cable communication 4a according to one of the embodiments described previously, each module 2 can send the spatial information to the module 2 (or to the modules 2) to which it is physically interconnected. The modules 2 which receive the information will add to their spatial information (and the relative identification code) that of the module(s) 2 connected to them, transmitting it to the nearby modules 2. In this way, the spatial information and the identification code will pass through all the modules connected to them until reaching the modelling unit 5.

In this way the modelling unit 5 is able to reconstruct the connections between each module 2 so as to also be able to process the orientation of each module 2 relative to the adjacent ones in order to obtain a correct virtual representation of the mechanical structure obtained with the interconnection of the modules 2.

Alternatively, with a communication using, for example, a radio system (such as UWB or RFID), there will be a direct communication between the modules 2 and the modelling unit 5.

In other words, the modelling unit 5 can identify the relative space position of the modules 2 as well as their orientation in space (as a function of the type of sensor used). The modelling unit 5 thus receives the spatial information of each module 2 and is thus able to assess the shape and overall dimensions of the mechatronic system assembled.

Alternatively, the single module 2 can be equipped with at least one antenna (or three) whilst the modelling unit 5 comprises three antennas (or one); in this way, the modelling unit 5 is able to triangulate the distances between the antennas for calculating the relative position between modelling unit 5 and modules 2.

As mentioned above, the above-mentioned embodiments can be combined with each other as a function of the system to be made and its specific use.

The invention also relates to a method for making and/or prototype production of self-configuring systems.

The method comprises preparing at least one module 2 as described above, therefore comprising the structural element 3, the at least one sensor (according to any one of the solutions described above) and the at least one transmitter 4 (according to any one of the solutions described above). The method also comprises preparing a modelling unit 5 (in the form of a dedicated device or software installed on a control terminal).

Once the elements forming the modular system 1 have been prepared, the method comprises measuring, using the at least one sensor, spatial information (as defined above) of the structural element 3.

The spatial information, as well as an identification code of the structural element 3, are at this point transmitted by means of the at least one transmitter 4 to the modelling unit 5.

The methods for transmitting spatial information can comprise one or more of the examples described above in this invention, with particular reference to the at least one transmitter 4 of the modular system 1.

The modelling unit 5 processes, as a function of a preset reference system, the spatial information and the identification code transmitted by the at least one transmitter 4.

The processing step will allow a correct virtual representation of the mechanical structure to be obtained.

If, as described above, a plurality of modules 2 are provided interconnected in succession, the transmission step comprises transmitting the spatial information and the identification code from each transmitter 4 of the plurality of modules 2. In particular, according to the method, each transmitter 4 transmits to a transmitter 4 of an adjacent module 2. In this way, each module 2 sends the spatial information and the identification code to a module 2 (or modules 2) to which it is physically interconnected, thus adding their information to that of the subsequent module 2 (or modules 2). In this way, the spatial information will pass through all the modules 2 connected to them until reaching the modelling unit 5 which is thus able to process the information in such a way as to obtain a correct virtual representation of the mechanical structure obtained with the interconnection of the modules 2

Advantageously, the modular system 1 described above makes it possible to overcome the drawbacks of the prior art.

Advantageously, the modules 2 described above comprise the sensors necessary to identify their position and their orientation in a three- dimensional space, even in the absence of an electrical connection.

Advantageously, the shape of the structural elements 3 allows beam-like structures to be made which can be designed by means of the theories of mechanical beam design, thus resulting in a smaller computational task by the modelling unit 5.

Advantageously, the modules 2 can be disassembled easily and reused in the production of new structures.

Still more advantageously, the modular system 1 allows a rapid prototype production of mobile robots and/or other automatic systems, reducing costs and production times both from a point of view of construction of the structure and modelling for the production of security, management and control software of the mobile robot or automatic system.

Advantageously, the modular system 1 described above allows various types of structures to be made such as, for example, components for 3D printers which do not therefore have the need to program the control software of the printing system.