EARLIEST PRIORITY DATE:

This Application claims priority from a patent application filed in India having Patent Application No. 202121044210, filed on September 29, 2021 and titled “A MATERIAL LAYING ROBOTIC SYSTEM”

FIELD OF INVENTION

Embodiments of the present disclosure relate to material laying, and more particularly, to a material laying robotic system.

BACKGROUND

Construction is one of biggest industry economically, and most important to support the population explosion. But is also the least automated industry which makes it least productive, and the working environment is dull, dirty and dangerous. In a conventional construction, masonry wall laying is performed manually using bricks, blocks, mortar, adhesive, and the like which makes such an approach slow, time consuming and labor- intensive process. Also, a mason bend about or more than 1000 times per shift and works in a tight, ergonomically challenging condition along with picking, laying block at height, due to such limitations, the block masonry is slow, intensive and inaccurate. In addition to this applying mortar, troweling of mortar, pick and place of bricks or blocks, bending also causes a lot of soft tissue injury and other musculoskeletal injures all over the body of the mason, thereby making the masonry one of the top professions that cause musculoskeletal injuries during work. Also, masonry is a skill full that need more than 1000 hrs of training and due the afore said reason skilled masonry force is decreasing. In order to increase the masonry efficiency, and reduce material wastage. Blocks are being used instead of bricks. The block is CMU, AAC, concrete and are 10-15 time bigger in size and 3-5 time heavier. This makes material handling much harder and challenging during laying of these blocks.

In comparison to the conventional approach, a newer approach uses robots to simplify the process of construction. However, the robots in the newer approach, are bulky and weigh more the 1.5 tons and lay small brick not large blocks. These machines are big, are attached to some kind of truck, crane or Hydra for shifting from one place to another. These machines are not light and portable and hence can only be used for external construction. These machines cannot be moved from floor to floor or passage thorough doors.

Hence, there is a need for an improved material laying robotic system to address the aforementioned issues.

BRIEF DESCRIPTION

In accordance with an embodiment of the present disclosure, a material laying robotic system is provided. The system includes a storage unit including a material storage compartment configured to store the material and a horizontal conveyor unit operatively coupled to the multistorey compartment and configured to transport the material from a first location to a second location. The system also includes a telescopic boom comprising a rotary table, wherein the rotary table is configured to pick and place the material at a predefined location, upon receiving the material from the horizontal conveyor. The system also includes a robotic unit operatively coupled to the rotary table, wherein the robotic unit comprises an adhesive application unit, wherein the adhesive application unit comprises a hopper configured to store adhesive material of a predefined quantity. The system also includes a base unit including at least one of a chained track, at least four wheels, or a combination thereof, wherein the base unit is operatively coupled at the base section of the robotic unit and a levelling unit comprising one or more inertial sensors operatively coupled to the base unit, wherein the levelling unit is configured to level the robotic unit to compensate one or more irregularities, wherein the one or more irregularities are detected by the one or more inertial sensors. The system also includes a computing module operable by one or more processors, wherein the computing module is operatively coupled to the robotic unit. The computing module is configured to receive input data from one or more sources, wherein the input data is representative of at least one of one or more location dimensions of a location where the material is laid, one or more material dimensions of the corresponding material used in laying at the location and to compute a ratio of material dimension to location dimension to obtain a total requirement of the material used for construction of a pre-defined layout design upon verifying one or more attributes associated to the predefined layout design.

To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF DRAWINGS

The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

FIG. 1 is a schematic representation of a front view of a material laying robotic system in accordance with an embodiment of the present disclosure;

FIG. 2 is a schematic representation of an exemplary embodiment of a back view of the material laying robotic system of FIG. 1 in accordance with an embodiment of the present disclosure;

FIG. 3 is a schematic representation of another exemplary embodiment of a side view of the material laying robotic system of FIG. 1 in accordance with an embodiment of the present disclosure;

FIG. 4 is a schematic representation of another exemplary embodiment of a front view of the material laying robotic system laying blocks of FIG. 1 in accordance with an embodiment of the present disclosure;

FIG. 5 a is a schematic representation of another exemplary embodiment of an isometric view of the material laying robotic system representing a multiplane laser scanner of FIG. 1 in accordance with an embodiment of the present disclosure; FIG. 5b is a schematic representation of another exemplary embodiment of a side view of the material laying robotic system representing the multiplane laser scanner of FIG. 1 in accordance with an embodiment of the present disclosure; and

FIG. 5c is a schematic representation of another exemplary embodiment of a top view of the material laying robotic system representing the multiplane laser scanner of FIG. 1 in accordance with an embodiment of the present disclosure.

Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

Embodiments of the present disclosure relates to a material laying robotic system. In one embodiment, the material may be at least one of a brick, a block, or a combination thereof. In such embodiment, the material may be laid in a construction location or a construction site.

FIG. 1 is a schematic representation of a front view of a material laying robotic system (10) in accordance with an embodiment of the present disclosure. The system (10) includes a storage unit (20). The storage unit (20) includes a material storage compartment (30) is configured to store the material (40). In one embodiment, the material storage compartment (30) may handle and lay wall using 20-30kg of AAC-CMU size 60x20x (20,15,10) [LxHxB] in cm which is about 4 to 5 times heavier and 10-12 times bigger than a conventional approach. In another embodiment, the material storage compartment (30) may store regular bricks that weight 2-3kg.

The storage unit (20) also includes a horizontal conveyor unit (50) operatively coupled to the material storage compartment (30). The horizontal conveyor unit (50) is configured to transport the material (40) from a first location to a second location. In one embodiment, the first location corresponds to the horizontal conveyor unit (50) and the second location may correspond to a destination location. The system (10) also includes a telescopic boom (70) including a rotary table (60). The rotary table (60) is configured to pick and inedplace the material at a pre-defined location, upon receiving the material (40) from the horizontal conveyor unit (50). In one exemplary embodiment, the rotary table (60) may be configured to receive bricks or the blocks from the horizontal conveyor unit (50) and place the same in a pre-defined position.

Furthermore, the system (10) includes a robotic unit (80) operatively coupled to the rotary table (60). The robotic unit (80) includes an adhesive application unit (90). The adhesive application unit (90) includes a hopper (100) configured to store adhesive material of a predefined quantity. In one exemplary embodiment, the adhesive material may be mortar. In such embodiment, the adhesive application unit (90) may include a mortar extruder or spray er/nozzle in fluid communication with the hopper, which is configured to apply the mortar to one or more sides of the brick according to the preferences. In one specific embodiment, the telescopic boom (70) may be configured to push the brick or the blocks towards the adhesive application unit (90).

In one exemplary embodiment, the system (10) may further include a laser scanning unit (150) comprising a plurality of laser scanners, wherein each of the plurality of laser scanners is operatively coupled to at least one of a top section, a side section or at a level same level of the base section of the robotic unit (80). The laser scanning unit (150) is configured to check the relative position of at least one of the robotic unit (80), surrounding environment of the location, at least one construction wall of the layout design, or a combination thereof.

In one exemplary embodiment, the system (10) may further include a pumping unit which may be operatively coupled to adhesive application unit (90) which may be configured to control flow and pumping mechanism of the adhesive material.

The system (10) also includes a base unit (110) which includes at least one of a chained track, at least four wheels, or a combination thereof, wherein the base unit (110) is operatively coupled at the base section of the robotic unit (80). The base unit (110) also includes a levelling unit (120) including one or more inertial sensors operatively coupled to the base unit (110), wherein the levelling unit (120) is configured to level the robotic unit (80) to compensate one or more irregularities, wherein the one or more irregularities are detected by the one or more inertial sensors. In one exemplary embodiment, the one or more inertial sensors may be configured to detect and stabilize the vibration and irregularities of the manipulator in real time. In one exemplary embodiment, the at least four wheels may be four wheels having holonomic drive, wherein each of the four wheels may have a traction and rotation and steering rotation. In such embodiment, each of the four wheels may be operated independently for proper movement of the base unit (110). In one embodiment, the levelling unit (120) may be operatively coupled to the robotic gripper.

In one exemplary embodiment, the levelling unit (120) may include a multi-plane laser configured for the dynamic last coordinate correction. In such embodiment, a laser unit along with the inertial sensors may be used to level the robotic gripper.

In one specific embodiment, the system (10) may include a scissor lifting unit (160) which is operatively coupled to a bottom section of the robotic unit (80), and configured to adjust a height of the robotic unit.

In another specific embodiment, the system (10) may include a linear manipulator (180) comprising a robotic gripper, wherein the robotic gripper comprises six degrees of freedom, wherein each of the six degrees of freedom is achieved by at least one dedicated motor, one or more brakes, one or more encoders, or a combination thereof, wherein the robotic gripper is configured to pick the material and place picked material at the predefined location.

Furthermore, the system (10) also includes a computing module (130) operable by one or more processors (140). The system (10) also includes a computing module (130) operable by one or more processors (140). The computing module (130) is operatively coupled to the robotic unit (80). The computing module ( 130) is configured to receive input data from one or more sources, wherein the input data is representative of at least one of one or more location dimensions of a location where the material is laid, one or more material dimensions of the corresponding material used in laying at the location. In one embodiment, the one or more sources may be an internal source, an external source, or a combination thereof. In such embodiment, the input may be in a form of a CAD design, or the like, which may be pre-structured by one or more authorized entities.

The computing module (130) is also configured to compute a ratio of material dimension to location dimension to obtain a total requirement of the material used for construction of a pre-defined layout design upon verifying one or more attributes associated to the predefined layout design. More specifically, the computing module (130) may compute the total amount of material required for building a specific kind of structure based on the input received. In such embodiment, the computation may be achieved using at least one of a machine learning technique, an artificial intelligence technique, or a combination thereof.

FIG. 2 is a schematic representation of an exemplary embodiment of a side view of the material laying robotic system of FIG. 1 in accordance with an embodiment of the present disclosure. The FIG represents the robotic unit (80) automatically laying bricks in the predefined location in a structured way using the input received comprising the layout design.

FIG. 3 is a schematic representation of another exemplary embodiment of a side view of the material laying robotic system of FIG. 1 in accordance with an embodiment of the present disclosure. The figure represents the laser scanner projecting the laser light at a specific direction within the pre-defined location. The reflected light is received by the laser scanning unit (150) to check the relative position of at least one of the robotic unit (80), surrounding environment of the location, at least one construction wall of the layout design, for safety and obstacle avoidance or a combination thereof.

FIG. 4 is a schematic representation of another exemplary embodiment of a front view of the material laying robotic system (10) laying blocks of FIG. 1 in accordance with an embodiment of the present disclosure. The robotic unit (80) lays the blocks upon receiving the input data from the computing module (130) to obtain a structure as defined in the predefined layout design.

Turning to FIGs. 5a, 5b and 5c, FIG. 5ais a schematic representation of another exemplary embodiment of an isometric view of the material laying robotic system representing a multiplane laser scanner of FIG. 1 in accordance with an embodiment of the present disclosure. FIG. 5b is a schematic representation of another exemplary embodiment of a side view of the material laying robotic system representing the multiplane laser scanner of FIG. 1 in accordance with an embodiment of the present disclosure. FIG. 5c is a schematic representation of another exemplary embodiment of a top view of the material laying robotic system representing the multiplane laser scanner of FIG. 1 in accordance with an embodiment of the present disclosure. The figure shows the laser being projected in various directions to check the relative position of at least one of the robotic unit (80), surrounding environment of the location, at least one construction wall of the layout design, or a combination thereof.

In operation, a computing device such as but not limited to a tablet, a mobile phone, or the like is coupled to the robotic unit (80) in order to transmit the layout design and other inputs for the robotic unit (80) to automatically lay the material in the required location. Further, based on the received input, the computing module may compute the total material required for constructing the specified deign as per the layout design. Consequently, the robotic gripper pics and holds the material and lays the same in the location upon marking a reference point for layout design. Subsequently, the laser scanning unit (150) checks the relative position of at least one of the robotic unit (80), surrounding environment of the location, at least one construction wall of the layout design, or a combination thereof in order to analyse and monitor data received by the laser scanning unit ( 150) in real time to match the real time material laying with the layout design.

In one exemplary embodiment, the system (10) may further include a notification module (170) operable by the one or more processors (140). The notification module is configured to generate a notification representative of at least one of the position of the material laid in the pre-defined position of the layout design. In one exemplary embodiment, the notification may be in a form of an alarm, a text message, a voice message, a pop up, or the like.

Furthermore, upon completing the laying of the material, the a laser scanning unit (150) may scan the entire layout to verify the proper laying of the material as per the initially received layout design. Various embodiments of the present disclosure enable the system to automatically lay the material in a desired location. Also, the overall weight of the system is reduced to a greater extent thereby making the transportation of the system easier. The system ensures quick block masonry, thereby making the system more reliable and efficient. The strain the mason undergoes is also eliminated by the system.

While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.