U.S. patent application number 16/552875 was filed with the patent office on 2020-02-27 for automated construction robot systems and methods.
The applicant listed for this patent is Ascend Robotics LLC. Invention is credited to DAVID ASKEY, Daniel Posfai.
Application Number | 20200064817 16/552875 |
Document ID | / |
Family ID | 69583243 |
Filed Date | 2020-02-27 |
View All Diagrams
United States Patent
Application |
20200064817 |
Kind Code |
A1 |
ASKEY; DAVID ; et
al. |
February 27, 2020 |
AUTOMATED CONSTRUCTION ROBOT SYSTEMS AND METHODS
Abstract
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.
Inventors: |
ASKEY; DAVID; (Salem,
MA) ; Posfai; Daniel; (Rockport, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ascend Robotics LLC |
Cambridge |
MA |
US |
|
|
Family ID: |
69583243 |
Appl. No.: |
16/552875 |
Filed: |
August 27, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62723137 |
Aug 27, 2018 |
|
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62851336 |
May 22, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G05B 2219/50391
20130101; B25J 9/162 20130101; G05B 2219/40298 20130101; B25J 18/02
20130101; B25J 11/0075 20130101; B25J 9/1682 20130101; B25J 9/1661
20130101; G05B 19/4155 20130101; B25J 9/1669 20130101; B25J 9/1697
20130101; G05B 2219/45013 20130101; B25J 5/00 20130101; B25J 9/1612
20130101 |
International
Class: |
G05B 19/4155 20060101
G05B019/4155; B25J 11/00 20060101 B25J011/00 |
Claims
1. A variable-duty-cycle microcontroller, configured for use within
an automated construction robot system, comprising: 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.
2. The variable-duty-cycle microcontroller of claim 1 wherein the
coating supply system includes an internal chamber within the
automated construction robot system.
3. The variable-duty-cycle microcontroller of claim 1 wherein the
coating supply system includes an external container
fluidly-coupled to the automated construction robot system.
4. The variable-duty-cycle microcontroller of claim 1 wherein the
coating material regulation system includes one or more valve
assemblies configured to selectively fluidly-couple the inlet port
and the outlet port.
5. The variable-duty-cycle microcontroller of claim 4 wherein the
one or more valve assemblies are configured to be selectively
energized and deenergized based, at least in part, upon the
variable-duty-cycle control signal.
6. The variable-duty-cycle microcontroller of claim 5 wherein
selectively energizing and deenergizing the one or more valve
assemblies based, at least in part, upon the variable-duty-cycle
control signal enables precise control of the quantity of coating
material provided to the outlet port.
7. The variable-duty-cycle microcontroller of claim 1 wherein the
coating supply system is a pressurized coating supply system.
8. The variable-duty-cycle microcontroller of claim 1 wherein: 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.
9. A variable-duty-cycle microcontroller, configured for use within
an automated construction robot system, comprising: 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.
10. The variable-duty-cycle microcontroller of claim 9 wherein the
coating supply system includes an internal chamber within the
automated construction robot system.
11. The variable-duty-cycle microcontroller of claim 9 wherein the
coating supply system includes an external container
fluidly-coupled to the automated construction robot system.
12. The variable-duty-cycle microcontroller of claim 9 wherein the
one or more valve assemblies are configured to be selectively
energized and deenergized based, at least in part, upon the
variable-duty-cycle control signal.
13. The variable-duty-cycle microcontroller of claim 12 wherein
selectively energizing and deenergizing the one or more valve
assemblies based, at least in part, upon the variable-duty-cycle
control signal enables precise control of the quantity of coating
material provided to the outlet port.
14. The variable-duty-cycle microcontroller of claim 9 wherein the
coating supply system is a pressurized coating supply system.
15. An automated construction robot system comprising: 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.
16. The automated construction robot system of claim 15 wherein the
variable-duty-cycle microcontroller, includes: 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.
17. The automated construction robot system of claim 16 wherein the
coating material regulation system includes one or more valve
assemblies configured to selectively fluidly-couple the inlet port
and the outlet port.
18. The automated construction robot system of claim 17 wherein the
one or more valve assemblies are configured to be selectively
energized and deenergized based, at least in part, upon the
variable-duty-cycle control signal.
19. The automated construction robot system of claim 18 wherein
selectively energizing and deenergizing the one or more valve
assemblies based, at least in part, upon the variable-duty-cycle
control signal enables precise control of the quantity of coating
material provided to the outlet port.
20. The automated construction robot system of claim 16 wherein:
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.
Description
RELATED APPLICATION(S)
[0001] This application claims the benefit of the following U.S.
Provisional Application Nos.: 62/723,137, filed on 27 Aug. 2018 and
62/851,336, filed on 22 May 2019, their entire contents of which
are herein incorporated by reference.
TECHNICAL FIELD
[0002] This disclosure relates to automated robot systems and, more
particularly, to automated robot systems for use within the
building trades and the construction industry.
BACKGROUND
[0003] 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.
[0004] Unfortunately, certain industries have been slower to adopt
robotic technology. For example, the building trades and the
construction industry have been slower to utilizes such technology
due to the mobility requirements of the robots and the transient
nature of the job locations.
SUMMARY OF DISCLOSURE
[0005] Concept 5
[0006] In one implementation, 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.
[0007] One or more of the following features may be included. 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.
[0008] In another implementation, 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.
[0009] One or more of the following features may be included. 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.
[0010] In another implementation, 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.
[0011] One or more of the following features may be included. 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.
[0012] The details of one or more implementations are set forth in
the accompanying drawings and the description below. Other features
and advantages will become apparent from the description, the
drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS. 1A-1E are diagrammatic views of an automated
construction robot system according to an embodiment of the present
disclosure;
[0014] 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;
[0015] FIG. 3 is a diagrammatic detail view of the head assembly of
FIGS. 1A-1E according to an embodiment of the present
disclosure;
[0016] 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;
[0017] 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;
[0018] 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;
[0019] 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;
[0020] 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; and
[0021] 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.
[0022] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] System Overview
[0024] Referring to FIGS. 1A-1E, there is shown automated
construction robot system 10, wherein automated construction robot
system 10 may include mobile base assembly 12 configured to be
displaceable within work area 14. Examples of 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. One example of 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). Another example of 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).
[0025] Automated construction robot system 10 may include head
assembly 16 configured to process work surface 18. As will be
discussed below in greater detail, examples of work surface 18 may
include but are not limited to interior walls, exterior walls, trim
work, door assemblies, and window assemblies. As will also be
discussed below in greater detail, 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.
[0026] 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. Examples of 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.
[0027] Arm assembly 20 may include wrist assembly 22 configured to
enable the rotation of head assembly 16 with respect to arm
assembly 20. Examples of 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.
[0028] Arm assembly 20 may include rotation assembly 24 configured
to enable the rotation of arm assembly 20 with respect to mobile
base assembly 12. Examples of rotation assembly 24 may include any
assembly that allows for the rotation of arm assembly 20 about a
Z-axis.
[0029] 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. Examples of
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.
Examples of 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.
[0030] As will be disclosed below in greater detail, 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.
[0031] The instruction sets and subroutines of automated
construction robot process 34, which 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.
[0032] 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. For example, 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.
[0033] 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.
[0034] As is known in the art, 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. As
is known in the art, 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.
[0035] Concept 1 (Automated Application)
[0036] As discussed above, 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.
[0037] Accordingly and referring also to FIG. 2, 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.
[0038] Coating material 48 may be locally or remotely provided. For
example, automated construction robot system 10 may include an
internal chamber (e.g., internal chamber 50) within which coating
material 48 may be stored. For example, 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. Alternatively, automated construction
robot system 10 may be configured to receive coating material 48
from an external container. For example, 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) may be utilized by automated construction robot
system 10 to effectuate the cleaning of the same (wherein 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).
[0039] 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:
[0040] Controlling 102 the movement of mobile base assembly 12
within work area 14. For example, automated construction robot
process 34 may be configured to control 102 the movement of mobile
base assembly 12 in the X-axis (perpendicular to work surface 18)
and/or Y-axis (parallel to work surface 18). Specifically,
automated construction robot process 34 may be configured to
repeatedly move mobile base assembly 12 along the Y-axis to allow
for the continued application of coating material 48 to work
surface 18. [0041] Extending/retracting 104 arm assembly 20 with
respect to mobile base assembly 12. For example, automated
construction robot process 34 may be configured to extend/retract
104 arm assembly 20, resulting in the displacement of head assembly
16 in the X-axis, Y-axis and/or Z-axis and the positioning of head
assembly 16 with respect to work surface 18. [0042] Controlling 106
the location of head assembly 16 with respect to work surface 18
and/or mobile base assembly 12. For example, automated construction
robot process 34 may be configured to control arm assembly 20,
wrist assembly 22 and/or rotation assembly 24 to control 106 the
location of head assembly 16 with respect to work surface 18 and/or
mobile base assembly 12. Specially, automated construction robot
process 34 may control 106 the location of head assembly 16 to
e.g., move head assembly 16 along the Z-axis and apply coating
material 48 in vertical stripes along work surface 18. Further,
automated construction robot process 34 may control 106 the
location of head assembly 16 to e.g., move head assembly 16 along
the Y-axis and apply coating material 48 in horizontal stripes
along work surface 18. Additionally, automated construction robot
process 34 may control 106 the location of head assembly 16 to
e.g., move head assembly 16 along the X-axis (i.e., toward and away
from work surface 18) to vary the width of the stripe of coating
material 48 applied to work surface 18. [0043] Controlling 108 the
velocity of head assembly 16 with respect to work surface 18 and/or
mobile base assembly 12. For example, automated construction robot
process 34 may be configured to control the rate at which arm
assembly 20 moves, control the rate at which wrist assembly 22
moves and/or control the rate at which rotation assembly 24 moves
to control 108 the velocity of head assembly 16 with respect to
work surface 18 and/or mobile base assembly 12. Specifically, by
controlling 108 the velocity of head assembly 16 (with respect to
work surface 18), the thickness of coating material 48 applied to
work surface 18 may be regulated. [0044] Rotating 110 head assembly
16 with respect to work surface 18. For example, automated
construction robot process 34 may be configured to control wrist
assembly 22, thus enabling the rotation of head assembly 16 about
an X-axis, a Y-axis, and/or a Z-axis. For example, if head assembly
16 is positioned to generate a horizontal spray fan (as shown in
FIGS. 1A-1B) when applying coating material 48, head assembly 16
may be displaced in the Z-axis to generate a vertical stripe of
coating material 48. Alternatively, automated construction robot
process 34 may rotate 110 head assembly 16 ninety degrees about the
X-axis, thus positioning head assembly 16 to generate a vertical
spray fan (not shown) when applying coating material 48, thus
allowing head assembly 16 to be displaced in the Y-axis to generate
a horizontal stripe of coating material 48. [0045] Controlling 112
the angle of incidence (.THETA.) of head assembly 16 with respect
to work surface 18. Referring also to FIG. 3, the angle of
incidence (.THETA.) 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 (.THETA.) is 90 degrees. This
may result in a decrease in the crispness of the edges 152, 154 of
coating material 48 applied to work surface 18. However, 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 (.THETA.) 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). [0046] Controlling 114 a spray fan width (e.g., spray
fan width 158) of coating material 48 applied to work surface 18
via head assembly 16. For example, nozzle assembly 160 of head
assembly 16 may be a variable geometry nozzle assembly that is
configurable to allow for adjustment of spray fan width 158 (thus
allowing for the increase/decrease of spray fan width 158). [0047]
Controlling 116 the volume of coating material 48 provided to head
assembly 16. For example, 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 provided to head assembly 16, wherein
pump assembly 162 and/or variable-duty-cycle microcontroller
assembly 164 may be controllable by automated construction robot
process 34 (as will be discussed below in greater detail). [0048]
Controlling 118 the pressure of coating material 48 provided to
head assembly 16. For example, 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 118 the pressure of coating material 48 provided to head
assembly 16, wherein pump assembly 162 and/or variable-duty-cycle
microcontroller assembly 164 may be controllable by automated
construction robot process 34 (as will be discussed below in
greater detail).
[0049] Concept 2 (Generation of a Coating Plan)
[0050] As discussed above, 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.
[0051] Further and as discussed above, 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. When scanning target area 28 to 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.
[0052] Referring also to FIG. 4, automated construction robot
process 34 may be configured to process 200 target area information
30 to define work area coating plan 60. For this example, assume
that 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.
[0053] Once work area coating plan 60 is defined, 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. Generally, 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). For example, if the
first wall within work surface 18 is 10' high and 50' long (with a
4' wide by 7' high door located in the center of that first wall),
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.
[0054] Once coating plan instructions 62 are generated 202,
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). For
example, assume that head assembly 12 applies coating material 48
in e.g., a 12'' wide stripe. Accordingly, 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.
[0055] Depending upon how automated construction robot process 34
is configured, automated construction robot process 34 may overlap
these stripes of coating material 48 to ensure consistent
coverage.
[0056] Concept 3 (Automated Repair)
[0057] As discussed above, 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.
[0058] Further and as discussed above, 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. When scanning target area 28 to 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.
[0059] Referring also to FIG. 5, 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). As is
known, when drywall is installed, the seams and interior corners
are covered with a combination of joint tape and drywall compound.
And 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.
Further, 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.
[0060] And while all surface defects are supposed to be addressed
during the finishing of the drywall, surface defects are routinely
missed and need to be addressed prior to the application of coating
material 48. Evidence of such surface defects (e.g., surface defect
64) 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).
[0061] Examples of such surface defects (e.g., surface defect 64)
may include but are not limited to one or more of: [0062] A High
Spot within the Work Surface 18: For example, a portion of drywall
compound that was applied to work surface 18 may have been
insufficiently sanded, resulting in a high spot within work surface
18 that needs to be repaired. [0063] A Low Spot within Work Surface
18: For example, an insufficient quantity of drywall compound may
have been applied to work surface 18, resulting in a depression
within work surface 18 that needs to be repaired. [0064] A Crack
within Work Surface 18: For example, a joint within the drywall, or
an interior/exterior corner may be been insufficiently taped,
resulting in a crack within work surface 18 that needs to be
repaired. [0065] A Hole within Work Surface 18: For example, damage
to a piece of drywall may have occurred, resulting in a hole within
work surface 18 that needs to be repaired. [0066] A Protruding
Screw within Work Surface 18: For example, a drywall screw may have
been insufficiently set within work surface 18, resulting in a
protruding screw head within work surface 18 that needs to be
repaired. [0067] A Protruding Nail within Work Surface 18: For
example, a drywall nail may have been insufficiently set within
work surface 18, resulting in a protruding nail head within work
surface 18 that needs to be repaired.
[0068] Once a surface defect (e.g., surface defect 64) is
identified, 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.
[0069] Accordingly: [0070] A High Spot within the Work Surface 18:
For such a surface defect, the remedial instructions (e.g.,
remedial instructions 66) generated 252 by automated construction
robot process 34 may include: [0071] i. the sanding of work surface
18 to make the surface flat. [0072] A Low Spot within Work Surface
18: For such a surface defect, the remedial instructions (e.g.,
remedial instructions 66) generated 252 by automated construction
robot process 34 may include: [0073] i. the application of drywall
compound to work surface 18 to fill the depression; and [0074] ii.
the sanding of work surface 18 to make the surface flat. [0075] A
Crack within Work Surface 18: For such a surface defect, the
remedial instructions (e.g., remedial instructions 66) generated
252 by automated construction robot process 34 may include: [0076]
i. the application of drywall compound to work surface 18 to fill
the crack; and [0077] ii. the sanding of work surface 18 to make
the surface flat. [0078] A Hole within Work Surface 18: For such a
surface defect, the remedial instructions (e.g., remedial
instructions 66) generated 252 by automated construction robot
process 34 may include: [0079] i. the application of drywall
compound to work surface 18 to fill the hole; and [0080] ii. the
sanding of work surface 18 to make the surface flat. [0081] A
Protruding Screw within Work Surface 18: For such a surface defect,
the remedial instructions (e.g., remedial instructions 66)
generated 252 by automated construction robot process 34 may
include: [0082] i. the setting of the protruding screw; [0083] ii.
the application of drywall compound to work surface 18 to cover the
screw head; and [0084] iii. the sanding of work surface 18 to make
the surface flat. [0085] A Protruding Nail within Work Surface 18:
For such a surface defect,3 the remedial instructions (e.g.,
remedial instructions 66) generated 252 by automated construction
robot process 34 may include: [0086] i. the setting of the
protruding nail; [0087] ii. the application of drywall compound to
work surface 18 to cover the nail head; and [0088] iii. the sanding
of work surface 18 to make the surface flat.
[0089] Once the remedial instructions (e.g., remedial instructions
66) are generated 252, 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).
Generally, 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. For example, 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: [0090] Utilizing 256 head assembly 12 to sand the surface
defect (e.g., surface defect 64) identified. For example, if head
assembly 16 is configured to sand the surface defect (e.g., surface
defect 64) included within work surface 18, head assembly 16 may be
utilized to perform such sanding functionality. In the event that
head assembly 16 affixed to arm assembly 20 is not capable of
sanding the surface defect (e.g., surface defect 64) identified, a
head assembly capable of performing such sanding functionality may
be selected by arm assembly 20 from plurality of head assemblies
68. [0091] Utilizing 258 head assembly 12 to apply joint compound
to the surface defect (e.g., surface defect 64) identified. For
example, if head assembly 16 is configured to apply joint compound
to the surface defect (e.g., surface defect 64) included within
work surface 18, head assembly 16 may be utilized to perform such
joint compound application functionality. In the event that head
assembly 16 affixed to arm assembly 20 is not capable of applying
joint compound to the surface defect (e.g., surface defect 64)
identified, a head assembly capable of performing such joint
compound application functionality may be selected by arm assembly
20 from plurality of head assemblies 68. [0092] Utilizing 260 head
assembly 12 to apply joint tape to the surface defect (e.g.,
surface defect 64) identified. For example, if head assembly 16 is
configured to apply joint tape to the surface defect (e.g., surface
defect 64) included within work surface 18, head assembly 16 may be
utilized to perform such joint tape application functionality. In
the event that head assembly 16 affixed to arm assembly 20 is not
capable of applying joint tape to the surface defect (e.g., surface
defect 64) identified, a head assembly capable of performing such
joint tape application functionality may be selected by arm
assembly 20 from plurality of head assemblies 68. [0093] Utilizing
262 head assembly 12 to set a protruding drywall screw within the
surface defect (e.g., surface defect 64) identified. For example,
if head assembly 16 is configured to set the protruding screw
(e.g., surface defect 64) included within work surface 18, head
assembly 16 may be utilized to perform such screw setting
functionality. In the event that head assembly 16 affixed to arm
assembly 20 is not capable of setting the protruding screw (e.g.,
surface defect 64), a head assembly capable of performing such
screw setting functionality may be selected by arm assembly 20 from
plurality of head assemblies 68. [0094] Utilizing 264 head assembly
12 to set a protruding nail within the surface defect (e.g.,
surface defect 64) identified. For example, if head assembly 16 is
configured to set the protruding nail (e.g., surface defect 64)
included within work surface 18, head assembly 16 may be utilized
to perform such nail setting functionality. In the event that head
assembly 16 affixed to arm assembly 20 is not capable of setting
the protruding nail (e.g., surface defect 64), a head assembly
capable of performing such nail setting functionality may be
selected by arm assembly 20 from plurality of head assemblies
68.
[0095] Concept 4 (Contact Detection)
[0096] As discussed above, 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.
[0097] As discussed above, when scanning target area 28 to 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. 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).
Additionally and as discussed above, 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.
[0098] Referring also to FIG. 6, 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).
[0099] As discussed above, examples of 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. Accordingly, 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).
Additionally, touch sensitive bumper assemblies (e.g., bumper
assembly 68) may be included within base assembly 12 and configured
to detect 302 such a contact event.
[0100] When adjusting 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), automated
construction robot process 34 may effectuate one or more of the
following operations: [0101] Ceasing 306 movement of mobile base
assembly 12, head assembly 16 and/or arm assembly 22 upon sensing
such contact with the object (e.g., user 42). For example and upon
detecting 302 such a contact event, automated construction robot
process 34 may immediately cease 306 any and all movement of mobile
base assembly 12, head assembly 16 and/or arm assembly 22. [0102]
Reversing 308 movement of mobile base assembly 12, head assembly 16
and/or arm assembly 22 upon sensing such contact with the object
(e.g., user 42). For example and upon detecting 302 such a contact
event, automated construction robot process 34 may immediately
reverse 308 any and all movement of mobile base assembly 12, head
assembly 16 and/or arm assembly 22.
[0103] Concept 6 (Edge Detection & Instruction)
[0104] As discussed above, 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.
[0105] Further and as discussed above, 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. When scanning target area 28 to 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. As discussed above and for
this example, assume that work surface 18 is a room that includes
four walls, two doors, two windows, six electrical outlets and two
light switches.
[0106] Referring also to FIG. 7 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. As discussed above, 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.
[0107] Accordingly, automated construction robot process 34 may
process 350 target area information 30 to generate one or more edge
instructions (e.g., edge instructions 70). When processing 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: [0108]
Identifying 352 an object within target area information 30 to be
avoided. For example, automated construction robot process 34 may
process 350 target area information 30 to identify 352 objects
(e.g., walls, doors, windows, electrical outlets and light
switches) to be avoided within work surface 18. [0109] Processing
354 target area information 30 to generate one or more edge
instructions (e.g., edge instructions 70) for applying coating
material 48 to work surface 18 while avoiding the identified object
(e.g., walls, doors, windows, electrical outlets and light
switches) within work surface 18.
[0110] 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). As discussed above and
referring again to FIG. 3, the angle of incidence (.THETA.) 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 (.THETA.) is 90 degrees. This 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). However, 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 (.THETA.) 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.
[0111] Accordingly and when manipulating 356 the angle of incidence
(.THETA.) 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), automated construction robot process
34 effectuate one or more of the following operations: [0112]
Rotating 358 head assembly 16 about an X-axis, which would enable
automated construction robot process 34 to e.g., switch spray fan
150 between a horizontal orientation and a vertical orientation.
[0113] Rotating 360 head assembly 16 about a Y-axis, which would
enable automated construction robot process 34 to e.g., adjust the
crispness of edges 152, 154 of coating material 48 applied to work
surface 18 when spray fan 150 is vertically orientated. [0114]
Rotating 362 head assembly 16 about a Z-axis, which would enable
automated construction robot process 34 to e.g., adjust the
crispness of edges 152, 154 of coating material 48 applied to work
surface 18 when spray fan 150 is horizontally orientated.
[0115] Therefore and when manipulating 356 the angle of incidence
(.THETA.) 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), automated construction robot process
34 may effectuate one or more of the following operations: [0116]
decreasing 364 the angle of incidence (.THETA.) to increase the
crispness of an edge (e.g., edges 152 and/or edge 154) of coating
material 48 applied to work surface 18 (in the manner described
above). [0117] increasing 366 the angle of incidence (.THETA.) to
decrease the crispness of an edge (e.g., edges 152 and/or edge 154)
of coating material 48 applied to work surface 18 (in the manner
described above).
[0118] Concept 7 (Non-Target Area Scanning)
[0119] As discussed above, 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.
[0120] Further and as discussed above, 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. When scanning target area 28 to 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.
[0121] 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. These
non-target areas (e.g., non-target area 72 and/or non-target area
74) may be positioned proximate target area 28. For example,
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.
[0122] Referring also to FIG. 8 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. 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).
[0123] Further and as discussed above, 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). Generally, 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).
[0124] As discussed above, 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.
[0125] Examples of such applied coating material defects (e.g.,
coating defect 80) may include but are not limited to one or more
of: [0126] No Coverage: An area to which coating material 48 was
not applied at all (resulting in bare drywall), [0127] Light
Coverage: An area to which coating material 48 was applied too
thinly (resulting in partially bare drywall). [0128] Heavy
Coverage: An area to which coating material 48 was applied too
heavily (which may have resulted in a run or a sag).
[0129] When manipulating 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), 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).
[0130] 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:. [0131] Utilizing head assembly 16
to apply coating material 48 to the area to which coating material
48 was not applied at all. [0132] Utilizing head assembly 16 to
apply coating material 48 to the area to which coating material 48
was applied too thinly. [0133] Utilizing head assembly 16 to sand
the run/sag and to apply coating material 48 to the area that was
sanded to address the run/sag.
[0134] As discussed above, 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.
[0135] As discussed above, examples of such surface defects (e.g.,
surface defect 64) may include but are not limited to one or more
of: [0136] A High Spot within the Work Surface 18: For example, a
portion of drywall compound that was applied to work surface 18 may
have been insufficiently sander, resulting in a high spot within
work surface 18 that needs to be repaired. [0137] A Low Spot within
Work Surface 18: For example, an insufficient quantity of drywall
compound may have been applied to work surface 18, resulting in a
depression within work surface 18 that needs to be repaired. [0138]
A Crack within Work Surface 18: For example, a joint within the
drywall, or an interior/exterior corner may be been insufficiently
taped, resulting in a crack within work surface 18 that needs to be
repaired. [0139] A Hole within Work Surface 18: For example, damage
to a piece of drywall may have occurred, resulting in a hole within
work surface 18 that needs to be repaired. [0140] A Protruding
Screw within Work Surface 18: For example, a drywall screw may have
been insufficiently set within work surface 18, resulting in a
protruding screw head within work surface 18 that needs to be
repaired. [0141] A Protruding Nail within Work Surface 18: For
example, a drywall nail may have been insufficiently set within
work surface 18, resulting in a protruding nail head within work
surface 18 that needs to be repaired.
[0142] When manipulating 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), 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).
[0143] 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: [0144] Utilizing head assembly 16 to sand the surface
defect (e.g., surface defect 64) identified. [0145] Utilizing head
assembly 16 to apply joint compound to the surface defect (e.g.,
surface defect 64) identified. [0146] Utilizing head assembly 16 to
apply joint tape to the surface defect (e.g., surface defect 64)
identified. [0147] Utilizing head assembly 16 to set a protruding
drywall screw within the surface defect (e.g., surface defect 64)
identified. [0148] Utilizing head assembly 16 to set a protruding
nail within the surface defect (e.g., surface defect 64)
identified.
[0149] Concept 5 (Variable Duty Cycle Microcontroller)
[0150] As discussed above, 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.
[0151] Referring also to FIG. 9 and as discussed above, 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.
[0152] Variable-duty-cycle microcontroller 164 may include: [0153]
inlet port 450 configured to receive coating material 48 from the
coating supply system. Examples of such a coating supply system may
include an internal chamber (e.g., internal chamber 50) within
which coating material 48 may be stored and/or an external
container (e.g., external container 54) that may contain coating
material 48. This coating supply system may be a pressurized
coating supply system (e.g., it may include pump assembly 162) in
order to provide coating material 48 to inlet port 450 of
variable-duty-cycle microcontroller 164. [0154] outlet port 452
configured to provide a regulated quantity of coating material 48
to head assembly 16. [0155] coating material regulation system 454
configured to control the passage of coating material 48 from inlet
port 450 to outlet port 452, wherein coating material regulation
system 454 may be configured to process a variable-duty-cycle
control signal (e.g., control signal 456) provided by computational
system 32 and regulate the quantity of coating material 48 applied
to work surface 18 via head assembly 16. As will be discussed below
in greater detail, the variable duty cycle control signal (e.g.,
control signal 456) may be is configured to have an increased duty
cycle (e.g., control signal 456A) when an increased quantity of
coating material 48 is needed at outlet port 452. Conversely, the
variable duty cycle control signal (e.g., control signal 456) may
be configured to have a decreased duty cycle (e.g., control signal
456B) when a decreased quantity of coating material 48 is needed at
outlet port 452.
[0156] 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) 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). For example, automated construction robot
process 34 may be configured to monitor the pressure of coating
material 48 being applied to head assembly 16.
[0157] In the event that the pressure of coating material 48 being
applied to head assembly 16 is too high, the 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. For example, the variable duty cycle
control signal (e.g., control signal 456) may be adjusted to have a
decreased duty cycle (e.g., control signal 506B) when a decreased
quantity of coating material 48 is needed at outlet port 452.
[0158] Conversely, in the event that the pressure of the coating
material 48 being applied to head assembly 16 is too low, the
variable-duty-cycle control signal (e.g., control signal 456) may
be adjusted to regulate the pressure of coating material 48 being
applied to head assembly 16 upward. For example, the variable duty
cycle control signal (e.g., control signal 456) may be adjusted to
have an increased duty cycle (e.g., control signal 456A) when an
increased quantity of coating material 48 is needed at outlet port
504.
[0159] Accordingly, selectively energizing and deenergizing the one
or more valve assemblies (e.g., valve assemblies 458) 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.
[0160] Multiple Robots
[0161] As discussed above, 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.
[0162] Further and as discussed above, 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.
[0163] While the scanning of target area 28 and non-target area 72,
74 is discussed above as being accomplished via a single automated
construction robot system, this is for illustrative purposes only
and is not intended to be a limitation of this disclosure, as other
configurations are possible and are considered to be within the
scope of this disclosure. For example, 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). In such a configuration, 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.
[0164] As discussed above, 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. Additionally,
scout construction robot (e.g., scanning robot system 80) may be
configured to be wirelessly coupled to access point 44 via a
wireless communication channel established between scanning robot
system 80 and access point 44. Accordingly, 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.
[0165] General
[0166] As will be appreciated by one skilled in the art, 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.
[0167] Any suitable computer usable or computer readable medium may
be utilized. 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. In the context of this document, 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.
[0168] 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).
[0169] The present disclosure is described with reference to
flowchart illustrations and/or block diagrams of methods, apparatus
(systems) and computer program products according to embodiments of
the disclosure. It will be understood that each block of the
flowchart illustrations and/or block diagrams, and combinations of
blocks in the flowchart illustrations and/or block diagrams, may be
implemented by computer program instructions. These computer
program instructions may be provided to a processor of a general
purpose computer/special purpose computer/other programmable data
processing apparatus, such that the instructions, which execute via
the processor of the computer or other programmable data processing
apparatus, create means for implementing the functions/acts
specified in the flowchart and/or block diagram block or
blocks.
[0170] 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.
[0171] 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.
[0172] The flowcharts and block diagrams in the figures may
illustrate the architecture, functionality, and operation of
possible implementations of systems, methods and computer program
products according to various embodiments of the present
disclosure. In this regard, 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). It should also be noted that, in
some alternative implementations, 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. It will
also be noted that each block of the block diagrams and/or
flowchart illustrations, and combinations of blocks in the block
diagrams and/or flowchart illustrations, may be implemented by
special purpose hardware-based systems that perform the specified
functions or acts, or combinations of special purpose hardware and
computer instructions.
[0173] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the disclosure. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof.
[0174] The corresponding structures, materials, acts, and
equivalents of all means or step plus function elements in the
claims below are intended to include any structure, material, or
act for performing the function in combination with other claimed
elements as specifically claimed. The description of the present
disclosure has been presented for purposes of illustration and
description, but is not intended to be exhaustive or limited to the
disclosure in the form disclosed. Many modifications and variations
will be apparent to those of ordinary skill in the art without
departing from the scope and spirit of the disclosure. The
embodiment was chosen and described in order to best explain the
principles of the disclosure and the practical application, and to
enable others of ordinary skill in the art to understand the
disclosure for various embodiments with various modifications as
are suited to the particular use contemplated.
[0175] A number of implementations have been described. Having thus
described the disclosure of the present application in detail and
by reference to embodiments thereof, it will be apparent that
modifications and variations are possible without departing from
the scope of the disclosure defined in the appended claims.
* * * * *