Brick/block laying machine incorporated in a vehicle

A self-contained truck-mounted brick laying machine (2) is described. A truck (1) supports the brick laying machine (2) which is mounted on a frame (3) on the truck chassis. The frame (3) supports packs or pallets of bricks (52, 53) placed on a platform (51). A transfer robot can then pick up an individual brick and move it to, or between either a saw (46) or a router (47) or a carousel (48). The carousel is located coaxially with a tower (10), at the base of the tower (10). The carousel (48) transfers the brick via the tower (10) to an articulated (folding about horizontal axis (16)) telescoping boom comprising first boom element in the form of telescopic boom (12, 14) and second boom element in the form of telescopic stick (15, 17, 18, 19, 20). The bricks are moved along the folding telescoping boom by linearly moving shuttles, to reach a brick laying and adhesive applying head (32). The brick laying and adhesive applying head (32) mounts to element (20) of the stick, about an axis (33) which is disposed horizontally. The poise of the brick laying and adhesive applying head (32) about the axis (33) is adjusted and is set in use so that the base (811) of a clevis (813) of the robotic arm (36) mounts about a horizontal axis, and the tracker component (130) is disposed uppermost on the brick laying and adhesive applying head (32). The brick laying and adhesive applying head (32) applies adhesive to the brick and has a robot that lays the brick. Vision and laser scanning and tracking systems are provided to allow the measurement of as-built slabs, bricks, the monitoring and adjustment of the process and the monitoring of safety zones. The first, or any course of bricks can have the bricks pre machined by the router module (47) so that the top of the course is level once laid.

TECHNICAL FIELD

This invention belongs to the field of building construction, and relates to a pick and place machine to build a building from bricks or blocks.

BACKGROUND ART

The following discussion of the background art is intended to facilitate an understanding of the present invention only. It should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was part of the common general knowledge as at the priority date of the application.

The inventor previously described a brick laying machine in U.S. Pat. No. 8,166,727. In practice, as described, this required a large road-going machine to implement.

An early prototype brick laying machine, based on that described in U.S. Pat. No. 8,166,727, and built by the inventor, used a chain conveyor with brick holding clamps attached to the chain. This chain moved from the base of the machine, out along a boom, to the laying head system. There was a small chain take up mechanism to take up variations in chain length due to changes in boom geometry. The take up mechanism also allowed some independence between the brick preparation and the laying, however the relatively short length of the take up mechanism meant that the brick preparation and the laying head needed to be synchronised at least some of the time. This meant that the slowest process limited the progress of bricks through the chain. Depending on the process of the current bricks being laid, either the brick preparation or the laying head could be the slowest process.

The chain followed a relatively complex path around the boom and telescopic stick so that as the telescopic stick was extended, the total chain length remained the same. The chain had brick griping clamps attached to it, so as it wrapped back and forth, it took up considerable space. If the telescopic stick had many stages, the amount of space taken up by the chain and grippers would greatly increase, making the boom and stick assembly larger than is desirable for road transport.

A brick conveyor using flat belts was investigated by the inventor. This required a substantially level orientation of the boom and telescopic stick and would require other means of moving the bricks vertically to accommodate for the change in laying height as the structure is built course by course. It was also determined that some cut bricks could be quite short compared to their height and would be unstable if transported on a flat belt conveyor. In the case of a telescopic stick and boom, dealing with excess belt length would encounter the same problems as the chain conveyor.

It is therefore an object of this invention to provide a brick laying machine that could be incorporated into a road-going vehicle, and would overcome at least some of the aforementioned problems, while maintaining the utility of the inventor's previously described machines.

In this specification the word “brick” is intended to encompass any building element such as a brick or block, to be placed during the construction of a building or wall or the like.

SUMMARY OF INVENTION

In accordance with the invention, there is provided a brick laying machine incorporated in a vehicle, said machine having a foldable boom, foldable about at least one folding axis, said foldable boom being locatable in a folded stowed position longitudinally along said vehicle, and moveable to unfolded extended positions away from said vehicle; said boom having a near end arranged for pivotal movement about a first horizontal axis located on a turret, said turret being rotatable about a vertical axis; said foldable boom having first conveying apparatus to convey bricks therealong, to a brick laying and adhesive applying head located at a remote end of the foldable boom, and having fluid conveying apparatus to convey adhesive therealong, to an adhesive applicator located in said brick laying and adhesive applying head said machine having a carousel extending at least partially around said turret near the base thereof, said turret having second conveying apparatus to convey bricks vertically from said carousel to said first conveying apparatus, said carousel being rotatable about a vertical axis to present a brick for access by said second conveying apparatus; said machine having at least one brick machining tool located beside said stowed position and having a loading bay to receive packs of bricks; said machine having programmable brick handling apparatus to convey bricks one by one from said loading bay to said carousel, optionally via said at least one brick machining tool, as pre-programmed.

Preferably said first conveying apparatus comprises at least one shuttle equipped with a clamp to releasably hold a brick, said shuttle running along a track extending along said boom.

Preferably said foldable boom comprises a first boom element and a second boom element pivotable about a said folding axis spaced from said first horizontal axis, and parallel therewith.

Preferably each boom element has a said track and at least one said shuttle.

Preferably at least one of said first boom element and said second boom element, has further elements arranged in telescoping interconnection.

Preferably both said first boom element and said second boom element have further elements arranged in telescoping interconnection.

Preferably said elements are tubular, preferably rectangular or square in cross-section.

Preferably each element has a said track and one said shuttle arranged to run along said track, between opposed ends of each said element.

Preferably said tracks are arranged located internally inside said elements, and said shuttles run inside their respective elements.

Preferably said track runs along one side of a said boom element, and runs along an opposite side of an immediately interconnecting said boom element, so that the shuttle located in the tracks of both boom elements can locate opposite each other in order to effect transfer of a brick from the clamp of one shuttle to the clamp of the other shuttle.

Preferably a said track runs along one side of a said boom element, and runs along the same side of an adjacent said boom element connected about a said folding axis, and a pivoting shuttle equipped with a clamp to hold a brick is provided, pivoting about said folding axis, to transfer a brick between shuttles in boom elements connected about said folding axis.

Preferably said tracks in the aforementioned arrangement run along the lengths of the boom elements on the side opposite to the side where the folding axis is located.

Preferably the distal telescoping element of said first boom element is smaller in cross sectional dimensions than the interconnected element of said second boom element connected about said folding axis, and said distal telescoping element is offset relative to said folding axis, to substantially centrally align the pathway through said elements at the folding axis, when the elements are interconnected about said folding axis substantially in a straight line.

Preferably, in the shuttle in the interconnected element of said second boom element connected about said folding axis, the clamp there of includes a deviation in its arms to provide clearance for the intruding part of the distal telescoping element of said first boom element, when the elements are interconnected about said folding axis substantially in a straight line.

Alternatively, the distal telescoping element of said first boom element is different in cross sectional dimensions from the interconnected element of said second boom element connected about said folding axis, and the smaller of the elements is offset relative to said folding axis, to substantially centrally align the pathway through said elements at the folding axis, when the elements are interconnected about said folding axis substantially in a straight line. Preferably, in the shuttles in the boom elements connected about said folding axis, the clamp of the shuttle contained in the boom element having a greater cross-sectional size includes a deviation in its arms to provide clearance for the intruding part of the boom element with the lesser cross-sectional size, when the boom elements are interconnected about said folding axis substantially in a straight line.

Preferably said track runs along one side of one element, and runs along an opposite side of an immediate interconnecting telescoping element, so that the shuttles located in the tracks of both elements can locate opposite each other in order to effect transfer of a brick from the clamp of one shuttle to the clamp of the other shuttle.

Preferably the internal interconnecting telescoping elements have a void at their near ends opposite said track therein to allow their shuttles to access shuttles of outer tubular elements to enable the clamps thereof to transfer a brick there-between.

It will be understood that where there are three or more telescoping elements, the track of the first third and fifth elements will be located on one side of these elements, while the tracks of the second and fourth elements will be located on the opposite side. The shuttles will run along the length of the elements, at least as far as they have been telescopingly extended, passing a brick from one said element to the next, and so on, to effect transfer of the brick along the extent of the telescoping part of the folding boom.

At the folding axis of the two boom elements, the folding axis extends horizontally on the underside of the boom elements, and a pivoting shuttle pivots about the same folding axis. The tracks run along the top of the boom elements that are connected about the folding axis, with the clamps of the shuttles extending down away from the tracks. The clamp on the pivoting shuttle extends upward away from the folding axis. The tracks of the boom elements that are connected about the folding axis overlap in the same manner, so that a shuttle arrives at the folding junction with a brick, the pivoting shuttle clamps the brick before the shuttle moves away, the pivoting shuttle pivots as necessary to align with the next boom element and presents the brick to the shuttle in the next boom element, to effect transfer of the brick between the shuttles of the elements at the folding intersection.

Preferably the second conveying apparatus comprises a turret track extending vertically along said turret, said turret track having a shuttle with a turret shuttle clamp to clamp a brick, the shuttle conveying the brick from the carousel to the shuttle in the near end of the foldable boom.

Preferably the turret supports a brick rotating mechanism having a clamp to clamp a brick presented by said turret shuttle clamp, said brick rotating mechanism being provided to rotate a brick so that its longitudinal extent aligns with the longitudinal extent of said first boom element, for presentation to a said at least one shuttle.

Preferably the brick rotating mechanism has a clamp to clamp a brick, and is mounted about said first horizontal axis.

Preferably the carousel has a carousel clamp to clamp a brick received from the programmable brick handling apparatus. In use, the carousel is rotated to align its clamp with the clamp of the shuttle on the turret track, so the brick can be transferred from the carousel clamp to the turret shuttle clamp, before the turret shuttle transfers the brick along the turret track to reach the first shuttle of the foldable boom. Preferably the carousel clamp can pivot from a first position in which it receives a brick from the programmable brick handling apparatus to a second position in which it presents the brick to the turret shuttle clamp.

Preferably said turret, said carousel and said stowed position are located along a central longitudinal axis of said vehicle.

Preferably said at least one brick machining tool comprises a first brick machining tool including a saw located to one side of the stowed position, and a second brick machining tool including a router located to the other side of the stowed position.

Preferably said first brick machining tool includes a clamp located to clamp a brick on a side of a saw cutting blade position.

Preferably said first brick machining tool includes a clamp configured to clamp a brick on each side of a saw cutting blade position. In this manner the brick and the waste portion thereof are secured to prevent damage during the cutting action, and the cut brick and saw blade can be separated before the clamp releases the cut brick portions.

Preferably said first brick machining tool is contained in an enclosure with a cover providing access for placement and removal of a brick by said programmable brick handling apparatus.

Preferably said second brick machining tool is contained in an enclosure with a cover providing access for placement and removal of a brick by said programmable brick handling apparatus.

Preferably the second brick machining tool includes a clamp to clamp a brick, and an orientation assembly to orient the clamped brick in space to present to the router, to route slots and notches in bricks in order to chase cabling, or to mill bricks to a predetermined required height.

Preferably the router in the second brick machining tool is mounted on a tri-axis motion assembly for moving the router in any combination of movement in three dimensions. This is preferably in the x and y axes across the brick, and in the z axis into the brick.

Preferably the second brick machining tool includes a tool storage magazine spaced away from the clamp and orientation assembly and accessible by said router at a predetermined position of said tri-axis motion assembly, to access or store a routing bit or milling bit. The tool storage magazine may store a number of different bits to allow different cuts to be made by the router.

Preferably said brick laying and adhesive applying head is pivotally mounted for controlled rotation to the remote end of the foldable boom about a second horizontal axis located on a clevis, said brick laying and adhesive applying head having associated therewith a pivotable clamp to receive and clamp a brick presented by said first conveying apparatus, said pivotable clamp being pivotally mounted about said second horizontal axis; said brick laying and adhesive applying head supporting said adhesive applicator to apply adhesive to a brick presented by said pivotable clamp; said brick laying and adhesive applying head having a brick laying head mounted thereto by a mount located in a position away from said clevis, said brick laying head having a brick laying clamp moveable between a position to receive and clamp a brick held by said pivotable clamp, to a position in which said brick is released and laid.

Preferably said brick laying and adhesive applying head is pivotally mounted for controlled rotation to the remote end of the foldable boom about a second horizontal axis located on a clevis, said brick laying and adhesive applying head having associated therewith a pivotable clamp to receive and clamp a brick presented by said first conveying apparatus, said pivotable clamp being pivotally mounted about said second horizontal axis; said brick laying and adhesive applying head supporting said adhesive applicator on a distal end of a tongue member, said tongue member being housed in a sheath for linear movement to extend said adhesive applicator across a brick presented by said pivotable clamp, and retract said tongue within said sheath to withdraw said adhesive applicator away from said pivotable clamp; said brick laying and adhesive applying head having a brick laying head mounted thereto by a mount located in a position away from said clevis, said brick laying head having a brick laying clamp moveable between a position to receive and clamp a brick held by said pivotable clamp, to a position in which said brick is released and laid; said sheath extending away from said second horizontal axis, and substantially along said clevis toward said mount, to provide clearance between said sheath and said brick laying head in order to allow operation without interference.

Preferably, said tongue is rigid when extended obliquely or horizontally and freely deflectable in only one dimension upwardly about horizontal axes away from said second horizontal axis only (i.e. freely deflectable upwardly but not from side to side, much in the same way as a human finger is moveable, palm facing up). This restriction in movement allows controlled application of adhesive to a surface, which typically will be disposed horiziontally. Particularly it allows the adhesive applicator head to be moved linearly relative to the surface, in a controlled manner.

Preferably said sheath has a tip which is, in use located horizontally, so that said tongue extends horizontally from the tip of said sheath.

Preferably said sheath curves upwardly to extend between said mount and said second horizontal axis, and the tongue being freely deflectable about horizontal axes allows the tongue to move within said sheath.

Preferably said tongue is configured as a chain-link-type actuator, said chain-link-type actuator being linearly moveable by a driven sprocket to selectively extend and retract said tongue from said tip of said sheath.

Preferably said chain link type actuator comprises a chain having body portions attached to one side, said body portions having ends that contact ends of adjacent body portions preventing said chain folding about said horizontal axes in one direction away from a horizontal alignment of said chain.

Preferably said tongue comprises a plurality of body portions, each body portion having on a top surface at least one pivot mount with a transverse aperture extending horizontally there-through to provide a connection point for a chain link to an adjacent said pivot mount of an adjacent said body portion, each said body portion having opposed ends that contact ends of adjacent body portions, said tongue being foldable in one direction only about said transverse apertures, the opposed ends of adjacent body portions coming into contact preventing said tongue folding about said connection points in the opposite direction.

Preferably each said body portion has a channel extending longitudinally there-through, for routing services such as wiring and tubing for the transport of adhesive to said adhesive applicator. The channel may be an inverted u-channel with the pivot mounts being located on top of the web.

Preferably the channel is closed, to fully enclose said services extending longitudinally through said tongue.

Preferably there are two said pivot mounts located on top of each said body portion, one said pivot mount located near each opposed end of said body portion.

Preferably on each body portion, said pivot mounts are spaced apart from each other by the same longitudinal distance as the sum of the longitudinal distances from each to the closest end of said body portion. In this manner, the pivot mounts can form teeth of a cog on top of the assembled tongue, to be engaged by a driven sprocket to selectively extend and retract said tongue from said tip of said sheath.

Preferably the angle of the faces forming the ends of each said body portion relative to the longitudinal extent of the body portion add up to 180 degrees. Most preferably the face forming each end of each said body portion is at right angles relative to the longitudinal extent of the body portion. With either arrangement, the tongue can extend outward and be self supporting, and bendable upward only, about the chain links that interconnect them.

Preferably the pivotable clamp is mounted for rotation on the distal end of said second boom element.

Preferably said pivotable clamp is mounted on a linear sliding mount that has travel extending in a direction linearly through said second horizontal axis and normal thereto.

Preferably the brick laying head includes a robotic arm assembly with said brick laying clamp to grip and lay a brick.

Preferably the brick laying head includes a spherical geometry robot with said brick laying clamp to grip and lay a brick.

Preferably said brick laying head includes a linearly extendable arm depending downward, attached about a mount roll-axis to said mount, said mount roll-axis allowing controlled roll motion in said arm relative to said mount, said brick laying clamp being mounted for controlled motion to the end of said linearly extendible arm about a universal joint allowing controlled pitch motion and controlled roll motion in said brick laying clamp relative to said arm, and said brick laying clamp is mounted to said universal joint on a rotatable mount for controlled rotation about a yaw axis.

The mount roll-axis will normally be longitudinal relative to the extent of the boom that the brick laying and adhesive applying head is attached to, and disposed horizontally in normal operation, as controlled by a ram or the like that controls the pose of the brick laying and adhesive applying head relative to the remote end of the foldable boom.

Preferably said mount includes a mount pitch-axis allowing controlled pitch motion of said arm relative to said mount. The mount pitch-axis runs transverse to the longitudinal extent of the linearly extendable arm.

Preferably said universal joint has a first wrist-axis pivotable transverse to the longitudinal extent of said arm and a second wrist-axis disposed normal to said first wrist-axis, both wrist-axes being normal to said yaw axis.

Preferably said linearly extending arm includes a linear guide which connects with said mount for controlled linear movement to extend and retract said arm in order to move said brick laying clamp toward or away from said mount.

Preferably the brick laying clamp includes jaws that are independently moveable to clamp and unclamp a brick, and also selectively moveable in unison to offset the position of the jaws relative to the brick laying clamp. This allows the brick laying clamp to access a position to lay a brick, that may be up against an existing wall lying alongside one of the jaws of the brick laying clamp.

Preferably said brick laying machine includes a tracker component mounted to said brick laying and adhesive applying head, wherein said brick laying and adhesive applying head has said robotic arm assembly with said brick laying clamp to grip and lay a brick, and said brick laying machine uses a tracker system to measure the position of the tracker component and applies compensating movement to the robotic arm assembly to correct for variance between programmed tracker component position and measured tracker component position.

Preferably said brick laying machine includes a further tracker component supported on said brick laying clamp, and said brick laying machine uses a further tracker system to measure the position of the further tracker component and applies further compensating movement to the robotic arm assembly to correct for variance between programmed further tracker component position and measured further tracker component position

In accordance with another aspect of the invention, there is provided a machining tool for use in machining an item in an automated assembly line, said machining tool having a chassis on which a machine tool is supported, a clamp with at least one set of jaws to support an item to be machined, said at least one set of jaws being arranged for movement to adjust the position at which machining of said item takes place, an enclosure with at least one cover moveable between a closed position in which said enclosure is sealed to minimise egress of machining waste and noise and an open position in which said clamp may be accessed by a transfer arm with grippers to insert said item before a machining operation and to remove said item after said machining operation, and a dust extractor for debris removal from said enclosure, said dust extractor having an intake located in proximity to said machine tool and a suction hose to cause airflow entraining debris for removal.

Preferably said machine tool comprises a saw with a cutting blade, and said clamp is mounted on a table for sliding movement from said open position in which said clamp may be accessed by said transfer arm, through said cutting blade to cut said item.

Preferably said clamp is configured with two sets of jaws to clamp said item on each side of a saw cutting blade position. In this manner the item and the waste portion thereof are secured to prevent damage during the cutting action, and the cut item and saw blade can be separated before the clamp releases the cut brick portions.

Preferably said machine tool comprises a router mounted for sliding movement along three orthogonal axes, said clamp being located to clamp said item in proximity to said cover, and arranged to rotate said item about an axis normal to a spindle axis of said router.

Preferably said clamp is mounted to an orientation assembly to orient the clamped brick in space to present to the router, to route slots and notches in bricks in order to chase cabling, or to mill bricks to a predetermined required height.

Preferably said router is mounted on a tri-axis motion assembly for moving the router in any combination of movement in three dimensions, with one of the three axes being said spindle axis, and the other two axes being normal to each other and the spindle axis. These axes are preferably in the x and y axes across the brick, and in the z axis into the brick.

Preferably the machine tool includes a tool storage magazine spaced away from the clamp and orientation assembly and accessible by said router at a predetermined position.

Preferably said tool storage magazine is accessible by said router at a predetermined position of said tri-axis motion assembly, to access or store a routing bit or milling bit. The tool storage magazine may store a number of different bits to allow different cuts to be made by the router.

Preferably said tool storage magazine comprises a rotary magazine mounted about a horizontal axis and spaced to one side of said clamp.

The invention provides a truck mounted automated brick laying machine. In its most preferred form, the machine is configured so that the boom can be folded so that the truck is within standard road transport dimension limits for rigid body trucks, and so is able to drive on public roads without requiring any special arrangements such as wide vehicle escorts, special permits or the like.

In its most preferred form, the elements of the folded boom are telescoping, with the first boom element mounted to the truck having sufficient extension to reach the necessary elevation for the expected height of the building to be constructed, and the first boom element and second boom element preferably having sufficient combined extension to reach over the entire construction site.

When at the building site, the automated brick laying machine extends stabilising legs and unfolds the boom. A tracking system is then set up to measure the position and orientation of the laying robot on the end of the boom.

Optionally a laser scanning device fitted to the end of the boom can be moved over the slab in all areas where bricks will be laid. The scanning device scans the height and level of the slab to obtain a 3D profile. The control system compares the profile of the slab to the ideal designed shape of the slab, fits the designed slab position to the lowest measured level of the actual slab (discounting any small low areas that could be bridged by a brick) and calculates an amount and shape of material, if any, to be machined off each brick in the first course so that after being laid, the top of the bricks in the first course are level and at the correct height.

The boom tip is moved to automatically or semi automatically scan a concrete slab. The location of the automatic brick laying machine and the concrete slab is used to set working coordinate systems for the construction of a structure. The scan of the slab is also used to calculate machining of the bricks laid in the first course of the structure to correct for variations in the height, level and flatness of the slab.

Packs of bricks are loaded at the rear of the truck. Robotic equipment de-hacks (unpack) the bricks and moves them optionally to or from an automated saw, an automated 5 axis CNC router with automatic tool-changer or to a carousel that then transports the bricks to a slewing, articulated and telescopic foldable boom. The bricks are passed from one shuttle to another along the boom to an automated adhesive application robot that applies adhesive to the bricks.

A robotic flipper then inverts the brick and then a spherical geometry robot grasps the brick and lays it on a structure being built. The structure is built course by course. The automated brick laying machine uses a tracking system to measure the position of the tip of the boom and applies compensating movement to the spherical geometry robot so that the brick is laid in the correct 3D position.

The boom is provided with lifting hooks to assist with the manual placement of items such as lintels, door frames and window frames. Optionally the spherical geometry robot can automatically place items other than bricks such as lintels, door frames and window frames.

The router is used to rout grooves in bricks so that when the bricks are placed in the structure the grooves line up ready for the following insertion of pipes and or cables. The router may be used to sculpt bricks. The router may be used to machine the top or bottom of bricks to allow for height correction of a course or in particular to machine the first course bricks to correct for the variation of height, flatness and level in a slab or the footings.

The automated saw is used to cut bricks to length or to cut bevels. This allows the bricks to be laid in standard or intricate patterns.

A software control system is used to control the automated brick laying machine. The software control system is cognisant of which brick is being placed in which location, and the bricks are machined or cut according to their predetermined locations. Bricks can be machined in order to provide chasing for plumbing, electrical wiring and other services. Such a control system may be as described in the international patent application filed by the applicant titled “Computer Aided Design for Brick and Block Constructions and Control Software to Control a Machine to Construct a Building”, with priority claim from Australian patent application 2016902787, the contents of both of which are incorporated herein by cross reference.

The automated brick laying machine has computerised vision systems and/or physical measuring probes to measure the bricks and check for quality, size and geometric shape, thereby allowing the machine to automatically reject damaged or sub-standard bricks and automatically apply corrections to accurately lay bricks of sightly varying tolerance of shape or dimension.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring toFIG. 1, a truck1supports a brick laying machine2which is mounted on a frame3on the chassis (not shown) of the truck. The frame3provides additional support for the componentry of the brick laying machine2beyond the support that would be provided by a typical truck chassis. Referring also toFIG. 5, the frame3supports packs or pallets of bricks52,53. De-hacker robots can take rows of bricks off the pallets and place them on a platform51. A transfer robot can then pick up an individual brick and move it to, or between either a saw46or a router47or a carousel48. The carousel is located coaxially with a tower10, at the base of the tower10. The carousel48transfers the brick via the tower10to an articulated (folding about horizontal axis16) telescoping boom comprising first boom element in the form of telescopic boom12,14and second boom element in the form of telescopic stick15,17,18,19,20. Each element12,14,15,17,18,19,20of the folding telescoping boom has a shuttle located inside on a longitudinally extending track in the element, to transport a brick along the longitudinal extent of the element. The bricks are moved through the inside of the folding telescoping boom by the linearly moving shuttles. The shuttles are equipped with grippers that pass the brick from shuttle to shuttle. Referring toFIG. 4, elements15and17are shown, showing tracks25supporting shuttle26running along the length of element17, and showing tracks29supporting shuttle30running along the length of element15. Shuttle26has jaws27and shuttle30has jaws31, which alternately can grip a brick298. When the shuttles27and30are coincident both sets of jaws27and31can grip the brick298as the brick is passed from one shuttle26to the other shuttle30.

The end of the boom is fitted with a brick laying and adhesive applying head32. The brick laying and adhesive applying head32mounts by pins (not shown) to element20of the stick, about an axis33which is disposed horizontally. The poise of the brick laying and adhesive applying head32about the axis33is adjusted by double acting hydraulic ram35, and is set in use so that the base811of a clevis813of the robotic arm36mounts about a horizontal axis, and the tracker component130is disposed uppermost on the brick laying and adhesive applying head32. The brick laying and adhesive applying head32applies adhesive to the brick and has a robot that lays the brick. Vision and laser scanning and tracking systems are provided to allow the measurement of as-built slabs, bricks, the monitoring and adjustment of the process and the monitoring of safety zones. The first, or any course of bricks can have the bricks pre machined by the router module47so that the top of the course is level once laid.

For ease of understanding, headings will be used in the following discussion.

Truck

Referring again toFIG. 1, a vehicle in the form of a rigid body truck1is used as a base for the automated brick laying machine2. In the preferred embodiment the truck1is a 8×8, 8×6 or 8×4 rigid body truck manufactured for example by Volvo, Mercedes, Iveco, MAN, Isuzu or Hino. The truck has a typical driver's cabin54. In an alternative arrangement, a semi-trailer intended for connection to a prime mover using a fifth wheel, may be used instead of a rigid body truck. The brick laying machine2could be mounted on a trailer, but this removes the convenience of having it truck mounted.

Frame

A frame3forming a rigid chassis is mounted to the truck. The frame3supports a pair of forward legs4and a pair of aft legs5, one of each pair on each side of the truck. The legs4and5can telescopically extend outwardly, and hydraulic rams then push down feet6to provide stability to the automated brick laying machine2. In practice, the hydraulic rams will adjust by positioning the feet6so that the frame3and hence the rigid body truck1is positioned horizontally. This results in correct vertical alignment of the vertical axis9and the tower10which are described hereafter. It follows then, that this correct alignment ensures that, subject to deflection tolerances, the axis33at the end of the element20is horizontal, and then with correct adjustment of the poise of the brick laying and adhesive applying head32by the ram35, the base811of a clevis813of the robotic arm36mounts about a horizontal axis, and the tracker component130is disposed uppermost on the brick laying and adhesive applying head32.

An enclosure7forming an outer body is mounted to the frame3. The enclosure7provides some weather protection, noise isolation and guarding of moving parts. Referring toFIGS. 1, 2 and 6, the enclosure7is fitted with a pair of doors85,86that are open when the boom12and stick15are folded. When the boom12and stick15are unfolded, the top doors85,86are closed by moving door85to the right87and door86to the left88to provide a first level of rain protection and noise isolation.

Referring toFIGS. 2, 4, 5, the frame3supports a fold down platform8at its rear end. The fold down platform8is mounted at its lowermost extent to the frame3on hinges and is moved by electric or hydraulic rams (not shown) from the raised vertical position illustrated inFIG. 2to the lowered horizontal position shown inFIG. 4. The fold down platform8is provided, when it is in the horizontal position, to receive packs of bricks52,53that are placed on it by a telehandler or fork lift truck.

Layout

Referring toFIG. 5, the frame3has a brick saw module46mounted on the left hand side of the central longitudinal axis of the truck1, and has a router module47mounted on the right hand side of the central longitudinal axis of the truck1. Reference to left hand side and right hand side is in the same context as used with reference to a vehicle being left hand drive or right hand drive. The frame supports a carousel48in the center of the frame, located toward and behind the driver's cabin54of the truck1. The frame has a chute76located to the right of the transfer platform51, for disposal of reject bricks.

The invention could be arranged in a mirror image about the vertical centreline without deviating from the inventive concepts described.

Referring also toFIG. 8, the enclosure7has an enclosure frame63. The enclosure frame63supports a programmable brick handling apparatus in the form of a transfer robot64.

Services

A large capacity electric generator (not shown) is mounted to the truck1chassis or the frame3and is driven by the IC engine (not shown) of the truck1. The generator provides power to the electrical system of the automated brick laying machine2.

Referring toFIG. 5, the frame3supports a dust extraction system79. The frame3also supports a refrigerated liquid coolant refrigerator83and pump84. The liquid coolant system85is used to cool electronic components and electric motors (not shown). The frame3also supports an electrical and controls cabinet82.

Referring toFIG. 5, the frame3supports a first scraper55and a second scraper56. The scrapers are provided to shift packs of bricks placed on the fold down platform8onto a first de-hacker bay49and a second de-hacker bay50located on the rear of the frame3, immediately adjacent the fold down platform8.

Each scraper55,56has an extending arm57that moves out past the bricks on the fold down platform8and then is lowered and then the first scraper55, drags the first pack of bricks from the fold down platform8into the first de-hacker bay49.

Alternatively, a single scraper not shown could be provided with an arm that swings to a side or the opposite side to be able to drag bricks from either de-hacker bay.

Transfer Platform

The frame supports a transfer platform51, immediately forward of the first de-hacker bay49and the second de-hacker bay50. The transfer platform51is provided to temporarily place bricks for further processing.

In typical operation, a first de-hacker bay49is loaded with external bricks52that may be used for the external walls of a structure being built. The second de-hacker bay50is loaded with internal bricks53that may be used for the internal walls of the structure being built, in a double brick style construction. Either de-hacker bay49,50may be loaded with any type of bricks that are to be used for a structure being built, since the placement of the bricks is a matter for programming. In a single brick construction where internal framework is to be added manually afterwards, both de-hacker bays would accommodate the same type of brick. It should be noted that the present invention enables construction of brick walls significantly faster and usually at a cost below that of internal framed walls, so in most applications, the present invention would be used to build all of the walls of a structure.

Referring toFIG. 7, each de-hacker bay49,50is provided with a five axis Cartesian de-hacker robot58fitted with a gripper59to pick up a brick or a row of bricks. Each de-hacker bay49,50is provided with a camera60for a machine vision system61to measure the position and location of the top layer of bricks not shown in the de-hacker bay49. The machine vision system61may also detect defects in the bricks. The bi-rotary wrist62of the de-hacker robot enables bricks to be gripped and then re oriented. It also allows brick packs to be oriented in either direction and to correct for mis-alignment. For example, bricks that are packed laying down can be stood up before they are placed on the transfer platform51.

Each de-hacker robot58can pick up a row of bricks from a pack of bricks, or pick up a single brick, and move it to the transfer platform51.

Transfer Robot

Referring toFIG. 5andFIG. 8, the transfer robot64moves a brick between the transfer platform51and optionally to or from the saw46and/or router47, to the carousel48, or optionally to the chute76.

Additionally, referring toFIG. 16, the transfer robot64picks up single bricks65from the transfer platform51. The transfer robot64is a Cartesian robot with five axes and a gripper66fitted to it. The transfer robot64has longitudinal rails67,68mounted above the saw and router and fastened to the enclosure frame63. The transfer robot64has a transverse gantry158which slides in a longitudinal direction69. The gantry158slideably supports a carriage153that moves transversely, the carriage153slideably supports a tee column151that slides vertically. The tee column151slideably supports a carriage152that slides longitudinally. The tee column151allows the carriage152and the bi rotary wrist154to be moved beyond the longitudinal position that could be reached by a wrist not shown mounted directly to a vertical column not shown in place of the tee column151. The carriage152supports a bi rotary wrist154that can slew and tilt the gripper66.

The transfer robot64may perform a number of operations. Most frequently the transfer robot64picks up a brick65from the transfer platform51and delivers it to a gripper mounted on a carousel48which can rotate around a slewing ring11. Alternatively, the transfer robot64may pick up a brick65from the transfer platform51and deliver the brick65to the table70of the saw module46. Alternatively, the transfer robot64may pick up a brick65from the transfer platform51and deliver it to the gripper72of the router module47. Alternatively, the transfer robot64may pick up a cut brick73from the saw module46and transfer it to the gripper74of the carousel48. Alternatively, the transfer robot64may pick up a brick65from the router47and move it to the gripper74of the carousel48. Alternatively, the transfer robot64may pick up a brick off cut75or broken or damaged brick and deliver it to a brick rejection chute76(shown inFIG. 5). The brick rejection chute76may optionally be fitted with a brick crushing device to reduce the volume of brick waste.

Refer toFIGS. 26, 27, 28, 29for details of the saw46module. The saw module46has a rotating blade93mounted from its base300. A sliding table70supports a brick and moves the brick against the saw. The brick is held to the table70by a clamp assembly shown generally inFIGS. 28 and 29. For compactness, the clamp moves up and down99and also back and forth96so that it can be moved forward when a brick is being placed onto the table or picked up by the transfer robot. For smooth motion the table is supported on linear guide rails301,302,303,304and moved by a servo motor and belt assembly. A detailed description follows.

Table

Referring toFIG. 27in particular, the saw46has a base plate300, which is supported on the frame3. The base plate300is fitted with linear guides301,302,303,304. The linear guides301,302,303,304respectively support bearing cars (not shown) which support the moving table70. The moving table70is fitted with a drive bracket310. The base plate300supports a gearbox305which supports a servo motor306. Servo motor306drives the input of the gearbox305. Gearbox305has an output shaft (not clearly visible) which is fitted with a pulley307. The base plate300supports an idler pulley308. A toothed belt309is wrapped around pulleys307and308with its ends fastened to the drive bracket310. The servo motor306drives the gearbox305which drives the pulley307which drives the belt309which moves the table70to a predetermined position in which a brick is to be cut, and through the blade93to complete a cutting operation.

Saw Blade

The base plate300supports a bracket311which supports a motor312which drives a pulley313. The base plate supports a bearing housing314. The bearing housing rotatably supports a shaft315. The shaft315has a saw blade93fastened to it and a pulley316fitted to the opposite end of the shaft315. A belt317wraps around pulleys313and316. The motor312drives pulley313which drives belt317which drives pulley316which turns shaft315which rotates the saw blade93. The saw blade93rotates about a horizontal axis95transverse to the truck1.

The saw mechanism could be replaced with a band saw, reciprocating saw, a vibrating saw or a chain saw.

Clamp

Referring toFIG. 27, the moving table70is fitted with a clamping mechanism94for the clamping of bricks. The moving table70supports a column318, on which the clamping mechanism94is placed. Referring toFIG. 28, the column318supports a top plate319and a lower bearing housing324which supports a bearing325. Top plate319supports a servo motor320to drive a vertical leadscrew323. Servo motor320is fitted with a toothed pulley321. The top plate319provides a housing for a bearing322which rotatably supports a vertical lead screw323at its top end and the bottom end of the leadscrew323is supported by the bearing325in the lower bearing housing324. The leadscrew323is fitted with a pulley326. An endless toothed belt327is wrapped around pulleys321,326. Referring toFIG. 29andFIG. 28, column318supports a vertically disposed linear guide328. Linear guide328supports a bearing car329for vertical movement therealong. The bearing car329supports a mount plate330which supports a bearing car331and lead screw nut342. Lead screw nut342is engaged with lead screw323. Bearing car331supports a clamp frame332for horizontal movement.

Servo motor320rotates pulley321which moves belt327to drive pulley326which rotates the leadscrew323to vertically move the clamp frame332. Referring additionally toFIG. 9andFIG. 27, the clamping mechanism94has a first linear axis96parallel to the truck1longitudinal axis and this allows the clamping jaws97to be moved horizontally so that the transfer robot64can access a brick on the table70. The clamping mechanism94has a second vertical axis99that allows the clamping jaws97to be moved down toward the table70(down the column318) to clamp the brick98to the table70.

Refer toFIG. 29, clamp frame332is provided with a slot333to allow it to pass the saw blade93(shown inFIG. 27). Clamp frame332is fitted with rubber pads334,335, adjacent to the sides of the slot333, so that the rubber pads334,335may contact and securely clamp to the top face of a brick98(shown inFIG. 9). Referring toFIG. 28, clamp frame332supports a gearbox336which supports a servo motor335′. Servo motor335′ drives the input of the gearbox336. The output of the gearbox336is fitted with a pulley337. Clamp frame332supports idler pulleys338,339,340. Mount plate330supports a belt clamp plate341. A toothed belt342′ wraps around pulleys337,338,339,340and is clamped at both ends by belt clamp plate341to mount plate330. Servo motor335′ drives the gearbox336to rotate the pulley337which moves the toothed belt342′ to move the clamp frame332horizontally relative to the column318.

Cable Chains

Cable chains are used to route power and signals to the servo motors.

Column318supports a cable bracket343. A cable chain344has its first end348fastened to the enclosure100(shown inFIG. 26). Cable bracket343at its top end supports the second end of cable chain344. Cable bracket343also supports a first end of a cable chain345. Mount plate330supports a cable bracket346. Referring toFIG. 29, the second end of cable chain345is fastened to cable bracket346. Cable bracket346supports a first end of a cable chain347. The second end of cable chain347is fastened to the clamp frame332. Electrical cables are routed through cable chain344to servo motor320and then through cable chain345and347to servo motor335′ (shown inFIG. 28).

Enclosure

Referring toFIG. 26, an enclosure100is provided around the saw to contain dust. The enclosure100has an opening door354to allow the delivery or removal of a brick by the transfer robot64. The opening door354slides back and forth along linear guides348and349.

The base plate300is provided with an enclosure100. Enclosure100, on its top, supports linear guide348and on its inner side it supports linear guide349. Linear guide348slideably supports bearing cars350,351, (shown as hidden lines inFIG. 26). Linear guide349slideably supports bearing cars352,353(shown as hidden lines inFIG. 26). Bearing cars,350,351,352,353support a door354. Enclosure100, supports a motor mount plate356to support a servo motor355. Servo motor355is fitted with a pulley357. Enclosure100also supports an idler pulley358. A belt359is wrapped around pulleys357,358. The ends of belt359are fastened to the door354with a clamp plate360. Servo motor355drives pulley357which moves the belt359, which moves the door354.

When the door354is in its closed position361, the door354contains brick dust and noise within the enclosure100. When the door is in an open position362, it allows access for the transfer robot64to reach inside the saw46to place a brick73on the moving table70. The saw blade93rotates partially within a guard and dust extraction hood101(also shown inFIG. 9) that is connected to a pipe102that is connected to the dust extractor79(seeFIG. 5).

Router

5 axis CNC routers and 5 axis CNC machining centers are known in engineering and manufacturing. The router module47of the embodiment has a layout that is particularly compact in relation to the size of the brick being machined and compact in relation to the travel of the spindle. The layout of the router47has the advantage that the tool magazine391is easily accessed from the side of the truck1. The router has the advantage that the brick gripping mechanism72(seeFIG. 34) is integrated directly onto the rotary orientation mechanism. A hopper80(seeFIG. 30) is provided to collect brick dust and direct it towards a dust extraction suction hose. Moving parts of the router tool90are screened to isolate them from brick dust which may be abrasive and cause wear of machine parts.

Referring toFIG. 30, to obtain a narrow width of the router module47, the tool magazine391of the router module47is mounted concentrically with the trunnion axis454(seeFIG. 34), between the rotary orientation assembly366(seeFIG. 31) trunnion414and the trunnion support392. In prior art machining centres or routers, the tool magazine391is mounted on the outside of the trunnion support, thus requiring further travel of the router to reach the magazine, or the addition of a tool change arm not shown to transfer tools from the magazine to the spindle of the router. The advantage of the present invention is that having the trunnion support outside of the tool magazine, means the tool magazine is close to the working area of the spindle and the trunnion support is located beyond the reach of the spindle axis, but within a width of the machine that is required for clearance to spindle components.

Referring toFIG. 33, the router enclosure364is provided with a rear door388and a top door373to provide a large single opening for the passage of bricks to and from the router module47. The transfer robot64is located just above the router module47. Due to height limitations of the layout configuration, there is not room above the router module47, below the transfer robot64to place a brick in through a top opening door373. The brick must be transferred in from the opening of the rear door388. The brick is supported from above by the transfer robot64. The top door373provides an opening above the brick so that the transfer robot64can support the brick from above, once the brick is maneuvered to the orientation assembly366(seeFIG. 31).

Referring toFIGS. 30, 31 and 32, the router module47has a base363. The base363supports an enclosure364to contain dust, the tool magazine391for holding routing and milling tools, a 3 axis motion assembly365(seeFIG. 31) for moving the router tool spindle90(seeFIG. 32) to a desired cutting position, and the orientation assembly366(seeFIG. 31) to rotate and tilt the brick.

The router module47has a router base363supporting the tool change carousel in the form of the tool magazine391that can hold up to 24 router bit tools. The router module47has a tilting rotary table366, shown generally inFIGS. 34 and 35, which is fitted with an electric screw actuated gripper434,435. Referring toFIG. 10, the router module47is fitted with the enclosure364to contain dust and noise. The router module47is fitted with a dust hopper80. The hopper80is provided with a dust extraction pipe81at its base. The dust extraction pipe81is connected to the dust extractor79.

As can be seen inFIG. 5, the router47is arranged to provide clearance to the folded boom and laying head when they are in the folded transport pose.

Enclosure

A detailed description of the enclosure364follows. Refer toFIGS. 30 and 33. The enclosure364has a sliding door373on top thereof and a sliding rear door388, both provided for placing and removing a brick from the router, the brick entering via the opening of the rear door, with the top door opening providing access for the transfer robot. Enclosure364supports linear guides367,368. Linear guide367supports bearing cars369,370, and linear guide368supports bearing cars371,372. Bearing cars369,370,371,372support door373. Enclosure364supports a drive mount plate520. Drive mount plate520supports a gearbox374(seeFIG. 30). Gearbox374supports a servo motor375. Servo motor375is fixed to a large pulley376. Large pulley376is fixed to a small pulley377. Enclosure364supports an idler pulley378. A belt379wraps around pulleys376and378with its ends fixed to the door373by a clamp plate379.

Referring toFIG. 30, servo motor375drives gearbox374which rotates pulleys376,377that move belt379and belt390. Belt379moves door373horizontally to open and close the top of enclosure364. Belt390moves rear door388(seeFIG. 33) vertically to open and close the rear end of enclosure364. The top door373and rear door388move simultaneously.

Tool Magazine

Referring toFIGS. 30 and 31, the base363supports tool magazine391, on an upstanding column392that also forms part of the trunnion for the orientation assembly366(shown inFIG. 31). The tool magazine391can rotate tool grippers397to present them in a position so that toolholders398can be exchanged with the spindle510, thereby allowing different shaped cutting tools399to be used by the router, or a blunt cutting tool399to be replaced with sharp cutting tool399. Cutting tools399may be routing or milling tool bits or abrasive coated cutters such as diamond router bits.

Referring toFIG. 30, the base363supports the column392, which supports bearing393. Bearing393rotatably supports stub shaft394. Stub shaft394concentrically supports bearing395. Bearing395supports wheel396. Wheel396supports a plurality of tool grippers397. Tool grippers397hold tool holders398. In the preferred embodiment the tool holders398are BT30 or IS030 tool holders. Each tool-holder398holds a cutting tool399, which will typically be a tungsten carbide insert milling or routing cutter. The cutters could alternatively be abrasive grit coated cutters of tungsten carbide, diamond or CBN. Ceramic or CBN inserts could be used in place of tungsten carbide inserts.

Base363supports a servo motor/gearbox assembly with a small pulley (indicated generally at400). Small pulley forms a reduction drive with a large toothed pulley405driven by a toothed belt406. The large toothed pulley405is fixed to the wheel396of the tool magazine391so that the servo motor assembly400can move belt406which then rotates the wheel396, thereby presenting different tool-holders398to a tool transfer position407(shown inFIG. 31).

Orientation Assembly

Refer toFIG. 31. The orientation assembly366can grip a brick and rotate and tilt it to present the brick in any orientation for machining by the router. Referring toFIG. 34, which shows a close up of the orientation assembly366, the brick is held in clamp jaws434and435which can be rotated and also tilted by a trunnion414.

Referring toFIG. 31, orientation assembly366is provided with a frame408supported by base363. Referring toFIG. 32, the frame408supports servo motor409and bearing reducer410. Bearing reducer410is driven by an endless toothed belt411driving toothed pulley412. Bearing reducer has an output plate located along horizontal trunnion axis454(shown inFIG. 34). Servo motor409rotates the trunnion414of orientation assembly366about the horizontal trunnion axis454.

Refer toFIG. 34andFIG. 35. Trunnion414is built as a frame comprising a first end425with an end plate415, welded to a top plate416and a bottom plate417, a front plate418and a rear plate419. Top plate416is welded to a vertical plate420at the second end424(away from the first end425). At the second end424, top plate416is welded to vertical plate420and front plate418and rear plate419. End plate423is welded to bottom plate417and front plate418and rear plate419. A curved cover plate422covers the void between plates420and423, which contains a servo motor451. Plate423closes the second end424of the trunnion414.

Refer toFIG. 35. Top plate416supports a bearing reducer426. Bearing reducer426is fitted with a toothed pulley427at one end and a spacer428at the other end. The spacer428supports a gripper base429. Refer toFIG. 34. Gripper base429supports linear guides430,431which support bearing cars432and433respectively. Bearing car432supports jaw434and bearing car433supports jaw435. Jaws434,435support a plurality of rubber pads436to aid in gripping a brick. Jaw434is fitted with a lead screw nut437and jaw435is fitted with a leadscrew nut438(shown in hidden lines). Base429supports a bearing housing440. Base429supports a servo motor441. Servo motor441is fitted with a pulley442. Base429supports idler pulleys443,444,445. Bearing housing440supports a bearing which supports a leadscrew448. Leadscrew448supports pulley450. Leadscrew450engages lead screw nuts437,438. A belt446is wrapped around pulleys442,443,444,450,445, and passes between base429and linear guide430. Servo motor441rotates pulley442which moves belt446which rotates pulley450which rotates leadscrew448which moves the jaws434,435, together to clamp a brick or apart to release the brick.

Refer toFIG. 35. Trunnion414supports a servo motor451internally, under the cover plate422. Servo motor451is fitted with a pulley452. Endless toothed belt453is wrapped around pulleys427and452. Servo motor451rotates pulley452which moves belt453which rotates pulley427which drives the input of bearing reducer426which then via its output rotates the base429of the gripper72.

Referring toFIG. 35spacer428supports a cable tube455. Cables456are routed through the trunnion414, then through the cable tube455, (refer toFIG. 34) through the groove456, under linear guide430to servo motor441.

It can be seen that the orientation assembly366rotates the trunnion414and therefore a brick 180 degrees through the trunnion axis454to present three adjacent faces of the brick oriented 90 degrees apart, while the base429can rotate the gripper through 180 degrees.

3 Axis Motion Assembly

Refer toFIGS. 31, 32, 36, 37 and 38. Referring toFIG. 31, the 3 axis motion assembly365moves the router tool90spindle motor510so that the spindle can machine a brick held in the gripper72. Linear guides and bearing cars such as Hiwin HGW or THK SHS series are used to provide sliding connections along the three axes. The 3 axis motion assembly365is moved by servo motors driving ball-screws through toothed belts. Movement could alternatively be provided by servo motors driving toothed belts, pinions engaged with racks, or by direct drive linear motors or other suitable means.

The 3 axis motion assembly365has a moving column463which can move from side to side along the x-axis709. The moving column463supports a carriage480which can move up and down along the y-axis710. The moving carriage480supports a ram487which can move back and forth. The ram487supports the spindle motor510, which holds and rotates the cutting tool399. The described 3 axis motion assembly provides rigid support of the spindle motor510and a very compact arrangement relative to the travel.

A detailed description of the 3 axis motion assembly365follows, referring toFIGS. 31 and 32. Base363supports linear guides457,458. Linear guide457supports bearing cars459,460(seeFIG. 32) and linear guide458supports bearing cars461,462(seeFIG. 32). Bearing cars459,460,431,462support moving column463. Moving column463supports a ball nut464which engages with a ball screw469. Base363supports a thrust bearing assembly473which secures an end of the ball screw469. Base393supports a mount block465(seeFIG. 32) having a bearing468to support the other end of the ball screw469. The mount block465supports a servo motor466fitted with a toothed pulley467which drives a pulley471(seeFIG. 32) fitted to the ball screw469via an endless toothed belt470. As ball-screw469is engaged with ball nut464, servo motor466translates moving column463along the x-axis709.

Referring toFIG. 36, moving column463supports linear guides474,475. Linear guide474slideably supports bearing cars476,477, and linear guide475slideably supports bearing cars478,479. Bearing cars476,477,478,479support carriage480shown inFIG. 37. Moving column463supports mount block481on which is mounted a servo motor482which drives a pulley483. Mount block481supports a thrust bearing484which supports a ball screw485at the lower end thereof. The ball screw485is supported at its upper end on a thrust bearing assembly487. The ball-screw485has a toothed pulley490which is driven by an endless toothed belt491connected with toothed pulley483.

Referring toFIG. 37, ram487has a bore509. Ram487supports spindle motor510shown inFIG. 38in said bore509. In the preferred embodiment the spindle motor510is an off the shelf cartridge spindle motor, for example HSD ES331. Spindle motor510has a conical taper511that accepts and clamps to the tool holders398(seeFIG. 30) by known means.

Cable Chains

Various servo motors and the spindle require the connection of pressurised air hoses, electrical power cables and signal cables. To support the hoses and cables, various cable chains are used. A detailed description of the support and routing of the cable chains follows.

Refer toFIGS. 31, 32, 37 and 38. Referring toFIG. 38, strut496supports a bracket512. Ram487supports a bracket513. Bracket512supports a first end of a cable chain514. Bracket513supports a second end of cable chain514.

Refer toFIG. 31. Base363supports a first end of a cable chain515. Moving column463supports a bracket516(Refer toFIG. 36for a larger view of bracket516). Bracket516supports a second end of cable chain515. Refer toFIG. 32. Bracket516supports a first end of cable chain517. Strut496supports a bracket518. Bracket518supports a second end of cable chain517(FIG. 37shows detail of bracket518).

Refer toFIG. 31, 32, 37, 38. Referring toFIG. 32, cables and hoses (not shown for clarity) are routed from the base363, through cable chain515, then through cable chain517and then through cable chain514. Referring toFIG. 5, cables not shown connect electrical power and signals from the control cabinet82to the servo motors466(seeFIG. 31),482(seeFIG. 32),503(seeFIG. 32) and the spindle motor510(seeFIG. 38). Referring toFIG. 38, ram487is provided with a hole519to provide access for electric cables and hoses to spindle motor510.

Vision System

A vision system is used to check that each brick handled by the transfer robot is of the correct size, shape, colour and texture and that any cuts, grooves or machining has been done correctly. The vision system also checks for cracks or large missing chips.

Refer toFIG. 8. The enclosure frame63supports machine vision cameras103,104on each side to view both sides of a brick65held by the transfer robot. The frame3supports a third camera157(shown inFIG. 4) to view the bottom of a brick65held by the transfer robot64and the enclosure frame63supports a camera105to view the top of a brick65held by the transfer robot. Note as drawn in the pose shown for clarity the brick65is not in the field of view of the machine vision cameras103,104,105,157. The enclosure frame supports laser line projectors106,107that project structured light onto a brick65held by the transfer robot64. The machine vision cameras103,104,105scan the 3D shape of the brick as it is moved by the transfer robot. Vision analysis, using for example Halcon 12 software is used to form a 3D model of the brick that is then compared to an expected 3D model of the brick to check that it is the correct size, of acceptable quality and that any saw cuts or routing cuts have been correctly made.

Volume scanners108,109(shown inFIG. 6) are placed at the rear of the truck1and enclosure7to ensure that no personnel enter a danger area such as the working envelope of the scrapers55,56(seeFIG. 5) or the internal volume of the enclosure7.

Carousel

Refer toFIGS. 1, 5, 8, 15 and 17. Referring toFIG. 1, the folding boom732can be rotated about a vertical axis9to point in any direction away from the truck. Referring toFIG. 8, the transfer robot64moves bricks to a location near the tower10(shown inFIG. 5) of the folding boom732(shown inFIG. 1). Referring toFIGS. 1 and 5, the carousel48receives bricks from the transfer robot, at a location approximately on the centreline of the truck, behind the tower10, and rotates about a vertical axis9to line the bricks up with the rotated folding boom732.

Referring toFIGS. 15 and 17, the carousel48receives bricks from the transfer robot64and passes them to a tower shuttle186sliding on the tower10. Referring toFIG. 15, the carousel has a ring frame166which rotates around the tower10(shown inFIG. 17). The ring frame166supports a gripper74that can tilt to receive a brick from the transfer robot64and then be rotated to line up with the tower shuttle186. A detailed description follows.

Referring toFIGS. 5 and 15, the frame3supports the carousel48. Referring toFIG. 15, the frame3supports a ring guide167which supports a plurality of rollers169that in turn support the ring frame166which is thus able to rotate about the vertical slewing axis9. The ring frame166supports a bracket170that in turn supports an arm165that rotates about a horizontal rotary axis77. The arm165supports the gripper74which has jaws171,172that move toward each other to hold a brick (not shown), or apart to release the brick. The ring frame166is rotated about the vertical axis9by a servo motor173and gearbox174that drives a pinion175engaged with a ring gear176fixed to the ring guide167. The bracket170supports a servo motor177that drives a gearbox178which moves the arm165. The arm165supports a servo motor179and a lead screw180. The servo motor179rotates the lead screw180. The jaws171,172are respectively fitted with lead nuts not shown that engage with the lead screw180. The ring frame166supports a cable duct185.

The frame3supports a cable guide181. The cable guide181supports a cable chain182. The cable chain182is connected at a first end183to the cable guide181and is therefore fixed relative to the frame3. The cable chain182has a second end184attached to the cable duct185. Electric current carrying cables (not shown) that carry power and control signals and sensor signals from the electric control cabinet82, are routed via the frame3, through the cable chain182to the cable duct185and then to the servo motors173,177,179.

The carousel48can move the gripper74from a pickup position where it receives a brick from the gripper66mounted on the transfer robot64, and rotate to a drop off position where it deposits a brick to the gripper jaws207,208on the tower shuttle186(shown onFIG. 17).

Tower

Refer toFIG. 5andFIG. 17. The frame3supports a slewing ring11at its front end78, located coaxially with the carousel48. Refer toFIG. 17. The slewing ring11supports a turret in the form of a tower10. The tower10can slew about the vertical axis9of the slewing ring11. The tower10supports the foldable boom732(shown inFIG. 1). The tower supports a tower shuttle186that moves bricks from the carousel48at the bottom end of the tower to the foldable boom732at the top of the tower10.

Refer toFIG. 17andFIG. 81. The tower10supports two parallel spaced linear bearing rails189,190. The linear bearing rails189,190respectively support four bearing cars191and192(and others occluded, not shown). The bearing cars191,192support a tower shuttle car193which in turn supports a gripper194. The gripper194may grasp a brick195. The tower10supports a servo motor196which drives a toothed pulley197that engages with and drives a belt198that is connected to, and thereby drives the tower shuttle186in a vertical direction. The tower10supports a servo motor199that drives a toothed pulley200that engages and drives a toothed belt201. Tower10supports an upper idler pulley202. Toothed belt201wraps around upper idler pulley202. The tower shuttle car193supports pulleys203and204. The tower shuttle car193supports a lead screw206. Leadscrew206is connected to a pulley205. The toothed belt201passes around pulley203, then drives pulley205and thus drives the lead screw206. The belt201passes around pulley204and then returns to pulley200. The tower shuttle car193slideably supports gripper jaws207,208. Gripper jaws207,208support lead screw nuts (not shown) that engage leadscrew206. Leadscrew206moves jaws207,208toward each other to grip a brick195, and in the opposite rotational direction, moves jaws207,208apart to release the brick195.

Refer toFIG. 17. The tower10supports a lug209with a bore213having a horizontal axis214, the bore receiving a fastener to connect an end of hydraulic ram22(shown inFIG. 1) to control the pose of the first boom12. Tower10supports clevis plates210,211which have a bore212with a horizontal axis13, about which the near end of the first boom is attached for pivoting movement (shown inFIG. 1).

Refer toFIG. 1. The foldable boom732is articulated and telescopic so that it can position the laying head throughout a large working volume, far from and close to the truck, both low and high so that the laying head can reach all courses of the structure to be built, both near and far, low and high.FIG. 76Ashows the foldable boom732in a folded pose for transport.FIG. 76Bshows the foldable boom732with the first boom12raised and the stick assembly744vertical.FIG. 76Cshows the foldable732with the stick assembly744horizontal with the telescopic sections extended.FIG. 76Cshows a pose that could be used to build a multi storey structure.FIG. 76Dshows the foldable boom assembly732with the first boom12raised above horizontal and the stick assembly744lowered slightly below horizontal.FIG. 76Eshows the foldable boom732at its maximum extension with both the first boom12horizontal and the stick assembly744horizontal.

The foldable boom732allows motion through a big envelope free of singularities and poles. A pole is a position within a robot's envelope that requires rapid rotation of one or more robot joints to maintain consistent orientation of the end effector, for the end effector to pass along a trajectory that passes through the pole. A singularity is a position or orientation, or a set of positions and orientations within the envelope that cannot be reached, or where the joints of the robot become poorly behaved, unstable, or the joint positions are difficult to calculate. Normal industrial robots typically complete the same task over and over so that it is possible to design, or alter the trajectory and robot pose to be free and clear of poles and singularities or to pass through a pole with specified rotation of the pole axis. The automated brick laying machine however must be able to complete a variety of tasks and any particular structure will require the boom to move through a large portion of its envelope, thus making a pole and singularity free working envelope desirable.

Shuttles within each section of the boom transport a brick along the inside of the boom. Shuttles pass a brick from a previous shuttle to the next. Rotators at each articulated joint of the boom move a brick from one boom element to the next, passing the brick from a previous adjacent shuttle to the next adjacent shuttle.

The bricks are passed by the shuttles, through the inside of the boom. The bricks are moved through the inside of the boom so that the boom structure contains the bricks and/or debris, in the unlikely event that a brick, or debris from a brick becomes loose from a shuttle. The boom structure provides convenient support to mount shuttles opposite each other. In the present invention within the telescoping elements of the boom and within the telescoping elements of the stick, the shuttles are alternately mounted above or below the brick, so that adjacent shuttles may move so that the grippers on the shuttles can both grasp a brick simultaneously and thereby transfer a brick from one shuttle to the next, without letting go of the brick.FIG. 82shows a partial view of the inside of the first boom element comprising first boom12and second boom14, with shuttle-B1224gripping a brick28from below and shuttle-B2531gripping a brick from above. The invention could alternately be arranged to support the shuttles from the sides of the boom. The invention could alternately be arranged to support the shuttles on the top of the boom, however it would then be desirable to fit an additional enclosure to boom to contain any dropped bricks or debris and the overall size of the boom would be larger or less structurally stiff.

First Boom Element

Referring toFIGS. 1 and 17, the tower10pivotally supports a foldable boom on clevis plates210and211for rotation about horizontal axis13. The foldable boom comprises a first boom element comprising first boom12and telescoping second boom14, and a second boom element comprising stick assembly744. First boom12can pivot about the horizontal axis13at the top of the tower10, and a sliding second boom14is telescopically able to slide within the first boom12.

Second Boom Element

Referring toFIG. 1, the second boom element744is pivotally connected about a horizontal axis16by an element in the form of an articulating first stick15to the distal end of the second boom14. The axis16is substantially parallel to the horizontal articulation axis13of the first boom.

A sliding second stick17is telescopically able to slide within the first stick15. A sliding third stick18is telescopically able to slide within the second stick17. A sliding fourth stick19is telescopically able to slide within the third stick18. A sliding fifth stick20is telescopically able to slide within the fourth stick19. Collectively first stick15, second stick17, third stick18, fourth stick19and fifth stick20form a stick assembly744also referred to as the second boom element.

The number of telescopic booms12,14or sticks15,17,18,19,20could be altered without deviating from the inventive concepts described. Collectively the tower10, booms12,14and sticks15,17,18,19,20form a foldable boom assembly732.

First boom12has a first near end269and a second distal end270shown inFIG. 18. First boom12is connected to the tower10(shown inFIG. 17) by a pin or pins not shown, through the bore212, in clevis plates210and211, connecting through apertures in first boom located at its near end269.

Lug209on the tower10is connected to the rod end of ram22by a pin (not shown). Ram22supports a trunnion mount215located a short distance along the first boom12from the near end269. The trunnion mount215provides boom lift lugs216,217. The articulated joint21of the tower10to the boom12about axis13is moved by ram22powered by electricity or hydraulics.

Refer toFIG. 24andFIG. 25. The tower10supports a brick rotating mechanism in the form of T-B1-rotator271. The T-B1-rotator271is used transfer a brick from the tower shuttle186to the first boom shuttle224(shown inFIGS. 19, 21 and 77D).FIG. 77Ashows the tower shuttle186holding brick298.FIG. 77Bshows the brick held by the T-B1-rotator271after receiving it from the tower shuttle186.FIG. 77Cshows the T-B1-rotator271moving to align itself with the first boom segment12.FIG. 77Dshows the T-B1-rotator271aligned with the first boom segment and shuttle-B1224moving into position under brick298. It should be understood that the boom will not necessarily be horizontal while this process occurs.FIG. 77Eshows the shuttle-B1224in position under the brick298. In this position the shuttle-B1224will grip the brick and the T-B1-rotator271will release the brick.FIG. 77Fshows the brick298held by the shuttle-B1224moving up the first boom segment12.FIG. 77Gshows the T-B1-rotator271moving into position to accept another brick from the tower shuttle186.

A detailed description of the T-B1-rotator follows.

Referring toFIG. 25, T-B1-rotator271has a bracket272which is fastened to the tower10(shown inFIG. 17). Bracket272supports a spacer274which supports a servo motor273. Servo motor273drives a pulley275. Bracket272supports idler pulleys276,277and a bearing reducer278. Bearing reducer278is fitted with an input shaft279which is fitted with a pulley280driven by servo motor273via an endless toothed belt281wrapped around pulleys275,276,277and280. Arm282is rotated by bearing reducer278about a horizontal axis290.

Bearing reducer278supports an arm282having a plate283depending therefrom at right angles. Plate283supports linear guides284,285. Linear guides284,285respectively support bearing cars286,287which respectively support jaws288,289provided to clamp a brick. Jaws288,289respectively are fitted with lead screw nuts296,297shown as hidden lines. Leadscrew nuts296,297engage with leadscrew293.

Arm282supports a servo motor291(not shown clearly inFIG. 25, but shown inFIG. 24) which drives a pulley292. Arm282supports a leadscrew293fitted with a pulley294. An endless toothed belt295is wrapped around pulleys292and294. Through this arrangement, servo motor291drives leadscrew293which is engaged with leadscrew nuts296,294to move jaws288,289together to grip a brick298or apart to release the brick298.

As can be seen in the drawings, and particularly in the sequence ofFIGS. 77A to 77G, the brick298is transported up the tower10with its longitudinal extent parallel with the vertical axis9of the tower10. The tower shuttle186holds the brick298in its gripper jaws207and208vertically above the body of the tower shuttle car193, so that the brick can be passed within reach of the jaws288,289of T-B1-rotator271. The T-B1-rotator271rotates the brick298so that its longitudinal extent is aligned with the longitudinal extent of boom12(and14). The T-B1-rotator271rotates about the same horizontal axis13as first boom12is mounted to the tower10. The location of this horizontal axis13is such that the shuttle-B1224is able to travel under the T-B1-rotator271to allow the transfer of the brick298from T-B1-rotator271to the shuttle-B1224.

First Boom

Refer toFIGS. 18, 19, 20. Referring toFIG. 18first boom12has boom lift lugs216,217welded thereto. Referring toFIG. 19, boom12is of a substantially rectangular or box cross section, and is constructed by welding bottom plate218to side plates219,220which are welded to top plate221. Removable panels (not shown) may be provided in convenient positions along any of the plates218,219,220,221, to provide access for servicing of internal componentry within first boom12. The bottom plate218supports a track in the form of channels222,223(also shown inFIG. 18). Channels222and223support shuttle-B1224. Referring toFIG. 18, shuttle224is shown gripping a brick225.

Shuttle

A shuttle grips a brick and is moved along the inside of the boom from the near end of the boom, nearly to the distal end of the boom, by toothed belts driven by servo motors fitted to the boom. The servo motors are fitted to the boom to minimise the size and weight of the moving shuttle and also to avoid having to use cable chains or slip tracks to transfer electrical power and signals to and from the shuttles. One servo motor256moves the shuttle and the other servo motor255moves the jaws of the shuttle. A detailed description follows.

Refer toFIGS. 18, 19 and 23. Referring toFIG. 23, bottom plate218supports a drive assembly254located at the distal end270of the first boom12. Drive assembly254has a body that supports servo motors255and256. Servo motor255drives a pulley258which drives an endless belt251. Endless belt251passes around idlers260,261. Plate218supports idler pulley assembly259(shown inFIG. 18) to turn the belt.

Servo motor256drives a pulley257. Drive assembly254has a shaft262that supports a large pulley263and a small pulley264, forming part of a reduction drive. An endless toothed belt258wraps around pulley257and large pulley263. A belt266wraps around pulley264and idler pulley assembly265at the near end269of first boom. Belt266, running the length of first boom12is driven by pulley264.

Refer toFIGS. 18, 21 and 22. Referring toFIG. 21, shuttle-B1224has a body246which supports wheels226,227,228,229that rotate about substantially horizontal axes, and supports wheels230,231,232,233that rotate about axes in a vertical plane. Shuttle-B1224supports linear guides234,235. Linear guides234,235respectively support bearing cars236,237which respectively support jaws238,239. Jaw238is provided with rubber gripping pads240,241and jaw239is provided with rubber gripping pads242,243. Jaws238,239respectively support lead screw nuts244,245at the base thereof (shown inFIG. 22). Body246supports bearing housings247,248(shown inFIG. 22) which support a leadscrew249. Referring toFIGS. 21 and 22, leadscrew249is fitted with a pulley250, located between the bearing housings247and248. Leadscrew249engages with leadscrew nuts244,245. Body246supports idler pulleys252,253. Tooth belt251, shown partially inFIG. 22and also inFIG. 23, wraps partially around pulley252, then pulley250then pulley253. Tooth belt251drives pulley250, which in turn rotates leadscrew249which moves the jaws238,239. Belt265is connected to body246at a first location267and a second location268. The drive train described allows servo motor255to move the jaws238,239together to clamp a brick225, or apart to unclamp a brick225. The drive chain described allows servo motor256to move the shuttle-B1 along the inside of first boom12. Thus a brick225can be clamped by a shuttle-B1224and moved from the first end269of first boom12to the second end270of first boom12and then brick225(shown inFIG. 18) can be unclamped. As servo motor256moves the shuttle-B1224along the boom, servo motor255must be synchronised with servo motor256to avoid the jaws238and239from inadvertent movement which could result in the brick being released or over-tightening of the jaws, or the shuttle jaws being run past their intended travel limits.

It will be seen in the discussion that follows, that the tracks, shuttles and drive assemblies of sticks15,17,18, and19follow the same fundamental configuration as that of boom12.

Winch

Winches and cables are used to move the telescopic sections of the boom and stick via a system of pulleys. The winch and cable system provides a very light weight means of moving the telescopic sections of the foldable boom. It was found that electric ball screws or hydraulic rams or toothed racks and gears could be used to move the telescopic sections of the boom, but these systems have a higher weight than the cable drive system described. The winch and cable system is detailed below.

Side plate219supports idler pulleys blocks722,723,724,725.FIG. 64shows a view of the boom12with side plate219and bottom plate218removed for clarity so that the second boom14can be seen more clearly. First boom12bottom plate218supports idler pulley blocks728,729,730,731. Second boom14bottom plate524supports idler pulley blocks726,727. Cable714passes in turn from the winch drum720to pulley block722then to pulley block723, then pulley block728then through pulley block726then pulley block731and then is fastened to the bottom plate524of second boom14. Cable714passes in turn from the winch drum720to pulley block724, then to pulley block725, then to pulley block729, then through pulley block727then through pulley block730and then is fastened to the bottom plate524of second boom14. The pulley blocks provide mechanical advantage so that a thin cable can be used. Servo motor719rotates the input of bearing reducer718which rotates the winch drum720which moves cables714,715which slides second boom14relative to first boom12.

Wear blocks799formed from ultra high molecular weight polyethylene (UHMPE) or other suitable material, are secured to the distal end of boom12and the near end of boom14to provide bearing surfaces for the elements to telescopingly slide. Wear blocks799of such material are described throughout this description to provide bearing surfaces for the telescoping parts of both the boom and the stick.

Second Boom

Referring toFIGS. 39, 40, 41, 42, 43, second boom14is of a substantially rectangular or box cross section. Referring toFIG. 39, second boom14is constructed by welding bottom plate524to side plates521,522, and welding side plates521,522to top plate523. As with the first boom12, removable panels (not shown) may be provided in convenient positions along any of the plates521,522,523,524, to provide access for servicing of internal componentry within second boom14. Second boom14has a first near end525and a second distal end526. Second distal end526supports lugs527,528. Referring toFIG. 40, top plate523supports channels529,530, which form a track to support shuttle-B2531.

Shuttle-B2531has jaws532,533for the gripping of a brick. Top plate523supports bracket assembly534, which supports idler pulleys535,536,537. Bracket assembly534supports servo motors538,539. Servo motor539drives the jaws532,533. Servo motor538drives the shuttle-B2531. Shuttle-B2531can move linearly from the first end525to the second end526of second boom14. The arrangement is the same as described for the first boom12except that the servo motors538and539are mounted externally on boom14to allow the channels529and530that form the track within second boom14to extend from the near end525, to the distal end526, so that the shuttle-B2531can traverse the entire length of second boom14.

Refer toFIGS. 11, 42 and 43. An arrangement of energy chains112is provided within the boom and stick assembly141to carry cables and hoses. Bottom plate524supports cable chains563,564,565.

The rotator-B2-S1548transfers a brick from the second boom shuttle to the first stick shuttle. It can rotate to align with either the second boom, or the first stick, to that the brick maintains orientation with its longitudinal extent extending with the first stick longitudinal extent, when the brick is transferred from the second boom12to the first stick15. The rotator-B2-S1548has movable gripper jaws to grasp the brick. A detailed description follows.

Referring toFIGS. 42 and 44, bottom plate524supports Rotator-B2-S1548from supporting bracket540. Bracket540supports bearing reducer541, which supports servo motor542. Bearing reducer542supports an assembly of arm543and base544. Base544supports mount plate547which supports servo motor549. Base544also supports linear guides545,546. Linear guide545supports bearing car550which supports jaw551. Linear guide546supports bearing car552which supports jaw553. Mount plate547supports bearing554(seeFIG. 42), which supports leadscrew555. Motor549has a toothed pulley556, and leadscrew555has a pulley557, with endless toothed belt558wrapped around pulley556and pulley557. Jaw551supports nut556′, and jaw553supports nut559(shown with hidden lines inFIG. 44). Leadscrew555engages with nuts556′,559. Servo motor549thus drives leadscrew555to move jaws551and553together to clamp a brick, or apart to release a brick. Servo motor542rotates the input of bearing reducer541. The output of bearing reducer541rotates arm543about a horizontal axis16, which is the same axis as the articulated joint23connection of second boom14to first stick15. Thus arranged, rotator548can grasp a brick located in shuttle-B2 at the second end526of second boom14and transfer it to a shuttle-S1 located at the first end561of first stick15.

Joint

Refer toFIG. 1. The articulated joint23of second boom14to first stick15about axis16is moved by a luffing ram24powered by electricity or hydraulics and a first dog bone link155and a second dog bone link156.

Refer toFIG. 45andFIG. 46. Side plate568supports lug586. Side plate569supports lug587. Side plate568supports boss588. Lugs586,587respectively have concentric bores589,590. Bores589,590are on axis16. Boss588has a bore591. Bore591supports a pin not shown that supports an end of dog bone link156.

First Stick

Refer toFIGS. 45, 46. First stick15has a first near end561and a second distal end566. First stick15is of a substantially rectangular or box cross section and welded plate construction, comprising a bottom plate567, welded to side plates568,569, and side plates568,569welded to top plate570. Side plate568supports lugs574,575for connecting an end of luffing ram24(shown inFIG. 1).

Stick Assembly

The stick assembly has telescopic sticks that can extend and retract. The extension and retraction is servo controlled. Each stick supports channels that in turn support shuttles that move bricks from a first near end to the next stick. The shuttles move back and forth on tracks within their respective sticks. The shuttles are provided with clamps, and can pass a brick along the stick assembly.

Stick Winch and Cables

The telescopic stick assembly is extended and retracted by a winch that winds cables that wrap around a system of pulleys to move the sticks. The winch is driven by a servo motor and bearing reducer. A detailed description follows.

Winch578is mounted to top plate570by bracket581and bracket582. A bearing reducer583is provided between servo motor584′ and a winch drum584. Bracket581supports a roller bearing585(not visible) that rotateably supports the winch drum584, at the end thereof away from the bearing reducer583. Top plate570supports pulley blocks746,747,748,749,750,751.

FIG. 68shows a view of the stick assembly744. Second stick17supports pulley blocks752,753. Third stick18supports pulley blocks754,755. Fourth stick19supports pulley blocks756,757. Extension cable580is wrapped on winch drum578and then passes through pulleys750,751, then to second stick17pulley block752, then to pulley block753, then to third stick18pulley block754, then to pulley block755, then to fourth stick19pulley block756, then to pulley block757, then to a termination758on fifth stick20. Tension on cable580forces the stick assembly744to extend.

Referring toFIG. 69, retraction cable579is wrapped on winch drum578and then passes through pulley blocks746,747,748and749and then runs internally inside stick assembly744to termination759on fifth stick20. Tension of cable579forces the stick assembly744to retract.

First Stick

Referring toFIGS. 45 and 46, the top plate570supports a track in the form of longitudinally extending channels571,572, inside the stick15. Channels571,572run from the first near end561of first stick15, nearly to the second distal end566, save room for the drive assembly592at the end of the track, inside the first stick15. Channels571,572slideably support shuttle-S1573. Shuttle-S1573has jaws576,577provided to clamp a brick.

Top plate570supports drive assembly592inside first stick15, in the same manner as that of the first boom12. Top plate570supports bracket593, which supports idler pulleys594,595,596,597. Servo motors not shown on drive assembly592move the shuttle-S1573along the top of and inside first stick15and can open and close jaws576,577to grip or release a brick. Thus shuttle573can grasp a brick at first near end561of first stick15and move it to or toward second distal end566of first stick15, then unclamp the brick not shown. The mechanism for this functions in the same manner as that of the first boom12and its shuttle. The jaws576and577each include a deviation576′ and577′ which aligns with the bracket assembly534of second boom14, to provide clearance to receive bracket assembly534at the distal end of second boom14, when the shuttle-S1573moves in to take a brick from rotator-B2-S1548when second boom14and first stick15are aligned in line, as shown inFIG. 79C.

Second Stick

Refer toFIGS. 47, 48, 49. Referring toFIG. 47, second stick17has a first near end598and a second distal end599. Second stick17is hollow and internally supports a shuttle that moves bricks from the first near end598to or toward the second distal end599.

Second stick17is preferably constructed from carbon fibre sandwich panels for low weight. Alternatively, second stick17way be welded with metal plates. Second stick17is of a substantially rectangular or box cross section. Second stick17is constructed by welding or bonding bottom plate600to side plates601,602. Side plates601,602are welded or bonded to top plate603. Bottom plate600supports a track formed by longitudinally extending channels604,605. Channels604,605support shuttle-S2606for movement therealong. Shuttle-S2606has jaws607and608to grasp a brick. Referring toFIG. 48, bottom plate600supports bracket609which supports idler pulleys610,611,612,613. Referring toFIG. 49, bottom plate600supports drive assembly614located at the distal end599of second stick17, which moves belts615and616, in order to move shuttle-S2606(shown inFIG. 48) and open and close jaws607,608, in the same manner as that of the first boom12and its shuttle. Thus shuttle-S2 can grasp a brick located at the first near end598of second stick17and move the brick to or toward the second distal end599of second stick17and unclamp the brick. The second stick17has a void in the top plate603at the near end598(shown inFIG. 48), which is opposite the track formed by channels604and605. This allows the shuttle-S1573of the first stick15to line up above the shuttle-S2606to enable the clamps thereof to transfer a brick from shuttle-S1573to shuttle-S2606.

Third Stick

Refer toFIGS. 50, 51 and 52. Referring toFIG. 50, third stick18has a first near end618and a second distal end619. Third stick18is preferably constructed from carbon fibre sandwich panels for low weight. Alternatively, third stick18may be constructed with welded metal plates. Third stick18is of a substantially rectangular or box cross section. Third stick18is constructed by welding or bonding bottom plate620to side plates621,622. Side plates621,622are welded or bonded to top plate623. Referring toFIG. 51, top plate623supports a track formed by longitudinally extending channels624and625which extend from the first near end618to the drive assembly634located at the second distal end619, shown onFIG. 52. Channels624,625support shuttle-S3626for movement along third stick18from first near end618to or toward second distal end619. Shuttle-S3626has jaws627and628, to clamp a brick. Top plate623supports bracket629. Bracket629supports idler pulleys630,631,632,633. Referring toFIG. 52, top plate623supports drive assembly634at the second distal end619, which moves belts635and636. Drive assembly634can move shuttle-S3626and open and close jaws627,628. Thus shuttle-S3 can grasp a brick located at the first end618of third stick18and move said brick to or toward the second end619of second stick18and unclamp the brick, in the same manner as that of the first boom12and its shuttle. The third stick18has a void in the bottom plate620at the near end618, which is opposite the track formed by channels624and625. This allows the shuttle-S2606of the second stick17to line up above the shuttle-S3626to enable the clamps thereof to transfer a brick from shuttle-S2606to shuttle-S3626.

Fourth Stick

Refer toFIGS. 53, 54, 55. Referring toFIG. 53, fourth stick19has a first near end637and a second distal end638. Fourth stick19is preferably constructed from carbon fibre sandwich panels for low weight. Alternatively, fourth stick19may be constructed from welded metal plates. Fourth stick19is of a substantially rectangular or box cross section. Fourth stick19is constructed by welding or bonding bottom plate640to side plates641,642. Side plates641,642are welded or bonded to top plate643. Bottom plate640supports a track formed by longitudinally extending channels644,645. Channels644,645extend from the near end637to drive assembly654located at the distal end, and support shuttle-S4646(shown onFIG. 54) for linear movement therealong. Referring toFIG. 54, shuttle-S4646has jaws647and648to grasp a brick. Bottom plate640supports bracket649at the near end637which649supports idler pulleys650,651,652,653. Referring toFIG. 55, bottom plate640supports drive assembly654at the distal end638, inside fourth the stick19. Drive assembly654moves belts655and656in order to move shuttle-S4646along fourth stick and open and close jaws647,648, in the same manner as that of the first boom12and its shuttle. Thus shuttle-S4646can grasp a brick located at the first end637of fourth stick19and move it to or toward the second end638of fourth stick19and unclamp the brick. Referring toFIG. 54, the fourth stick19has a void in the top plate643at the near end637, which is opposite the track formed by channels644and645. This allows the shuttle-S3626of the third stick18to line up above the shuttle-S4646to enable the clamps thereof to transfer a brick from shuttle-S3626to shuttle-S4646.

Fifth Stick

Refer toFIGS. 56, 57, 58 and 59. Referring toFIG. 56, fifth stick20has a first near end657and a second distal end658. Fifth stick20is preferably constructed from carbon fibre sandwich panels for low weight. Alternatively, fifth stick20may be constructed from welded metal plates. Fifth stick20is of a substantially rectangular or box cross section. Fifth stick20is constructed by welding or bonding bottom plate660to side plates661,662. Side plates661,662are welded or bonded to top plate663. Top plate663supports a track formed by longitudinally extending channels664,665, which extend from the near end657to the drive assembly663, along the inside of the fifth stick20. Referring toFIG. 57, channels664,665support shuttle-S5666for linear movement therealong. Shuttle-S5666has jaws667,668provided to grip a brick. Top plate663supports bracket669at the near end657which supports idler pulleys670,671,672,673. Referring toFIG. 58, top plate663supports drive assembly674at the distal end658. Drive assembly674moves belts675and676in order to move shuttle-S5666and open and close jaws667,668(shown inFIG. 57). Drive assembly674moves belts675and676in order to move shuttle-S5666along fifth stick and open and close jaws647,648, in the same manner as that of the first boom12and its shuttle. Shuttle-S5666can grasp a brick presented by shuttle-S4646located through a void located at the near end657of the bottom plate660. Shuttle-S5666then moves the brick along the inside of fifth stick20to the second distal end658of fifth stick20, where it will be unclamped.

The panels or plates making up each of the first stick15, second stick17, third stick18, fourth stick19and fifth stick20may be provided with removable panel portions (not shown) to provide access for servicing of internal componentry within each stick.

Boom Cable Chains

Cable chains are used to route power and signals to and from the servo motors. The arrangement of the cable chains provides a compact over all cross section of the folding boom.

First near end637of fourth stick19supports a first end737of cable duct733. Second end738of cable duct733supports a first end739of cable chain734. The bottom plate660of fifth stick20, supports the second end740of cable chain734. Cable chain734and cable duct733are also visible inFIG. 56.

Referring toFIG. 67, the bottom plate524of second boom14supports a first end743of cable chain564. The top plate643of fourth stick19supports a second end744′ of cable chain564. Cable chain564is also visible inFIGS. 39, 40, 41, 42.

Referring toFIGS. 1 and 5, cables (not shown) are routed from the electrical cabinet82through the frame3, through the centre of slew ring11, up through the inside of tower10and into first boom12, then into cable chain112(shown inFIG. 65), then into second boom14. Referring toFIG. 65, cables (not shown) are routed from second boom14, to first stick15, and to cable chain565and then into second stick17, and as shown inFIG. 66also into cable chain563and then into third stick18, and as shown inFIG. 67also into cable chain564and then into fourth stick19.

Referring toFIG. 65, (cables not shown) are routed from fourth stick19, through cable duct733into cable chain734then into fifth stick20. From fifth stick20, cables not shown are routed to the brick laying and adhesive applying head32.

Flipper

Refer toFIGS. 59, 60, 61. Referring toFIG. 59, a pivotable clamp in the form of a flipper assembly687has jaws690and693to grip a brick and can then translate and rotate the brick to move it past an adhesive application nozzle121,122,123,124and125and then present the brick for transfer to the laying arm. The flipper assembly687is located at the distal end658of the fifth stick20.

FIG. 80A to 80Qshow a sequence for a brick as it passes from the fifth stick to its laid position.

During the laying of bricks, the brick laying and adhesive applying head32is held at a constant tilt relative to the ground. The pose of the foldable boom is varied to position the brick laying and adhesive applying head32appropriately for the brick laying and adhesive applying head32to lay bricks in the required position. The angle of the stick assembly, varies according to the required pose of the foldable boom. The flipper assembly687is used to receive a brick from the stick assembly (FIG. 80A) and move the brick to a position suitable for an adhesive applicator777in the brick laying and adhesive applying head32to apply glue to said brick (FIGS. 80D-80G), and then for the brick laying gripper44to lay the brick (FIG. 80Q). Referring toFIG. 60, the flipper assembly687rotates about axis33. The flipper assembly687has a gripper with jaws690and693that can slide toward or away from the axis of rotation33(which is the same horizontal axis of the mount of the brick laying and adhesive applying head32to the end of fifth stick20). The gripper can extend into the fifth stick20to grasp a brick (FIG. 80B). The gripper then retracts to a position near the axis of rotation33(FIG. 80C) so that the brick is clear of the fifth stick20. The brick is then rotated for the application of adhesive (FIG. 80D). The adhesive application nozzles are extended out over the brick (FIGS. 80E, 80F). The adhesive nozzles direct adhesive downwards so that gravity assists in applying the adhesive to the brick. The adhesive application nozzles are retracted whilst directing adhesive onto the brick (FIG. 80G). The flipper687then rotates (FIG. 80H) to orient the brick vertically (FIG. 80J), so that adhesive application nozzles can apply adhesive to the end of the brick. The flipper then rotates (FIG. 80K) to invert the brick (FIG. 80L) so that the adhesive is on the bottom of the brick. The flipper687then extends the gripper out (FIG. 80M), to present the brick in a position where the brick laying gripper44can then grasp the brick (FIG. 80N). The flipper gripper then releases the brick and the flipper gripper then translates in a reverse direction whilst the flipper rotates in a reverse rotation (FIG. 80P, 80Q) so that the gripper is returned to its starting position (FIG. 80A).

A detailed description of the flipper assembly follows.

Refer toFIG. 59. Fifth stick20supports the flipper assembly687about the same horizontal axis33as the brick laying and adhesive applying head32is attached to the distal end of the fifth stick20(seeFIG. 80A).

Refer toFIGS. 58, 59, 60 and 61. Referring toFIG. 59the fifth stick20supports a bearing reducer677and a servo motor678. Bearing reducer677supports an arm679of the flipper assembly687on its output, and a servo motor678rotates the input of bearing reducer677. This rotates arm679and hence the flipper assembly687about axis33. Referring toFIG. 60, the arm679supports a linear guide680which slideably supports a bearing car681for movement between a first end707and a second end708of the arm679. A base plate682mounts to the bearing car681, perpendicularly to the travel extent thereof. Referring toFIG. 61, a servo motor684for movement of the base plate682is mounted via a spacer683to the arm679. Referring toFIG. 60, a servo motor686for movement of jaws690and693is mounted on motor mount plate685which is supported on base plate682. Base plate682supports linear guides688,689which slideably support bearing cars691and692respectively. Bearing car691supports jaw690, and bearing car692supports jaw693. Servo motor686drives pulley694which drives pulley696connected to leadscrew695via endless toothed belt697. Referring toFIG. 61, base plate682supports a bearing700which rotateably supports the leadscrew695. Referring toFIG. 60, jaw690supports a nut698, and jaw693supports a nut699, which nuts698and699are engaged with the leadscrew695. Thus servo motor685drives the jaws690and693to clamp and unclamp a brick.

Jaws690and693can be moved by servo motor684towards the second distal end658of fifth stick20to pick up a brick (seeFIG. 80B) that is being held by jaws667,668of shuttle-S5666. Servo motor686can then close jaws690and693to grasp the brick. Servo motor684can then move jaws690,693, holding the brick towards first end707of arm679(seeFIG. 80C). Servo motor678can then rotate arm679so that the top surface of said brick is presented flat, ready for adhesive application by the adhesive application system150(seeFIGS. 80D to G).

Optionally, servo motor684can then rotate arm679through 90 degrees so that the end of said brick is presented flat, ready for adhesive application by the adhesive application system150(seeFIGS. 80Hand J). It should be noted that in some structures, such as for walls that will be rendered, it is not necessary to apply adhesive to the vertical (or “perp”) joints of the bricks. Optionally, servo motor684can then rotate arm679through 180 degrees so that the opposite end of said brick is presented flat, ready for adhesive application by the adhesive application system150, thereby applying adhesive to the bottom and both ends of said brick.

Servo motor684can then rotate arm679through 180 degrees (or 90 or 270 degrees, depending on which faces of the brick had adhesive applied to them), so that said brick is inverted, ready to be picked up by the laying arm gripper44(seeFIGS. 80Kto Q). In this way the glue is applied to the bottom of said brick that will be laid by the laying arm40.

FIG. 75shows a side view of the brick laying and adhesive applying head32and fifth stick20.FIG. 75shows the sequence of the brick797from a first position791, to a second position792, to a third position793to a fourth position794to a fifth position795to a sixth position796. In first position791, brick797is gripped by shuttle-S5666(not shown inFIG. 75). The flipper jaws690and693are moved to grasp the brick797and then shuttle-S5666releases the brick797. The brick797is then translated to second position792, then rotated to third position793. Adhesive is then applied to the brick797. Brick797is then optionally rotated to vertical position794. Brick797is then rotated to a fifth position795and then translated to a sixth position796.

Adhesive

Referring toFIG. 5, the frame3supports an adhesive container110and an adhesive pump111. The adhesive pump111supplies pressurised adhesive to fluid conveying apparatus in the form of a hose which runs out along the boom and through the flexible energy chains112(shown inFIG. 65),564(shown inFIG. 67) and740(shown inFIG. 65) provided in the telescopic boom and telescopic sticks, to the brick laying and adhesive applying head32. Adhesives can be one pack or two pack, and should have some flexibility when set in order to avoid fracturing due to uneven expansion and contraction in the built structure. Suitable adhesives are single pack moisture curing polyurethane such as Sika “Techgrip”, Hunstman “Suprasec 7373” or Fortis AD5105S, single pack foaming polyurethane such as Soudal “Souda Bond Foam” or Weinerberger “Dryfix”, two part polyurethane such as that made by Huntsman, MS Polymer (Modified Silane Polymer) such as HB Fuller “Toolbox”, two part epoxy such as Latipoxy310 and methacrylate adhesive such as “Plexus”. It would be possible but less desirable (due to strength, flexibility and “pot life” and clean up reasons) to utilise water based adhesives such as latex, acrylic or cement based adhesives similar to various commercially available tile glue or Austral Bricks ‘Thin Bed Mortar”.

Refer toFIGS. 12 and 13. The adhesive applicator777has an adhesive head fitted with nozzles121,122,123,124and125, shown schematically inFIG. 13. The adhesive flow is controlled by electrically operable valves118and119, located in a manifold head117, close to the nozzles121,122,123,124and125, which are also supported on the manifold head117. Space within the laying head is very restricted. The nozzles provided in two groups comprising a central group of nozzles121,122and123supplied by valve118, and a peripheral group of two outer nozzles124and125supplied by valve119. The manifold head117is supported on a mechanism that can project the nozzles out to reach the length of a brick, and retract the nozzles to provide clearance so that the brick can be rotated and also by retracting the nozzles clearance is provided so that the laying head can be folded against a retracted stick assembly for compact transport. To achieve the extension and retraction, the nozzles are supported on a chain that can only bend one way and the chain is extended or retracted by a sprocket driven by a servo motor. A detailed description follows.

Refer toFIGS. 12, 13, 62 and 71. Referring toFIG. 62, the brick laying and adhesive applying head32supports an adhesive applicator assembly777. Referring toFIG. 71, the adhesive applicator assembly777has a curved guide113attached to the brick laying and adhesive applying head32. The curved guide113supports a tongue member in the form of a sliding chain114that can only bend one way. The sliding chain114is moved by a servo powered sprocket115. The brick laying and adhesive applying head32supports a straight guide784into which the sliding chain114may be retracted. The distal end116of the sliding chain114supports a manifold117that supports two valves118,119. Each valve118,119is connected to the pressurised adhesive supply120provided by the adhesive pump111mounted to the frame3(shown inFIG. 5). The first valve118is connected to three central glue nozzles121,122,123, and the second valve119is connected to two outer glue nozzles124,125(shown schematically inFIG. 13). The inner nozzles121,122,123are provided to allow glue to be applied to the top face of a narrow or internal brick, while the outer nozzles124,125allow glue to be applied to the outer edges of the top face of a wide or external brick126. The valves118,119may be operated individually or together to supply glue to the inner nozzles121,122,123, the outer nozzles124,125or all nozzles121,122,123,124and125. The adhesive is applied in a direction extending downwardly from the valves on the manifold, the manifold being disposed on the sliding chain114which is disposed horizontally.

Refer toFIGS. 72 and 73. Referring toFIG. 72, the sliding chain114has a plurality of body portions in the form of hollow links778and a plurality of chain links in the form of joiner links779. Joiner links779are standard items used to join power transmission chain, such as BS roller chain16-B1 or ANSI roller chain80-1. Referring toFIG. 73, hollow link778is provided with lugs780,781to engage the pins782of joiner links779shown inFIG. 72. Hollow link778is provided with a longitudinally extending hole783for the passage of cables (not shown) and the pressurised adhesive120(seeFIG. 13). The hollow links have ends that contact each other to prevent over extension of the sliding chain, allowing the sliding chain to be extended outward from the tip of the curved guide and retain a straight configuration, being bendable upward only, about the axes provided by the connection of the hollow links with the joiner links.

Referring toFIG. 74, the straight guide784is fitted with a lid788. InFIG. 71curved guide113is shown with the lid787removed for clarity. Straight guide784is shown without the lid788for clarity.

Referring toFIG. 72, consider the example of first hollow link778, joiner link779and second hollow link784′. It can be seen that second hollow link784′ can pivot upwards relative to first hollow link778, but second hollow link784′ cannot pivot downwards relative to first hollow link778. By extension of the logic to the plurality of hollow links778and joiner links779, the sliding chain114can only curve upwards and not curve downwards.

Preferably the hollow links778are manufactured from a material with a low coefficient of friction such as acetal copolymer or UHMWPE (Ultra High Molecular Weight Polyethylene) plastic. The curved guide113and straight guide784may be manufactured from a material with a low coefficient of friction such as acetal plastic.

FIG. 74shows a top view of straight guide784. The straight guide784is provided with grooves785,786so that joiner links779do not touch straight guide784. Straight guide784may then be constructed from a material such as aluminium alloy which is more robust than acetal plastic.

Referring toFIG. 71, the curved guide113is also provided with grooves789,790so that joiner links779do not touch curved guide113. Curved guide113may then also be constructed from a material such as aluminium alloy which is more robust than acetal plastic.

The tongue in sheath arrangement of the adhesive applicator allows a single axis of servo motion control to move a nozzle for application of adhesive whilst maintaining a vertical nozzle orientation and also to retract the nozzle to allow for movement of the brick to the next step of the process. The laying head space is quite limited, so to achieve the application and retraction with more conventional linear movement mechanisms or articulating arm robots would require the use of two or more servo axes of motion or the addition of linkages and cam mechanisms.

Brick Laying and Adhesive Applying Head

Refer toFIG. 62. The brick laying and adhesive applying head32supports a brick laying head in the form of a spherical geometry robot36and the adhesive applicator assembly777along with a vision system and tracking system. After application of adhesive as described above, the brick laying and adhesive applying head32takes a brick from the jaws690and693of the flipper assembly687and moves it to a position where it is laid. The laying head also compensates for movement and deflection of the boom, so that the brick is laid in the correct position.

Refer toFIGS. 1, 12 and 62. Referring toFIG. 62, the articulated brick laying and adhesive applying head32has a body801with arms803and805forming a clevis which extends obliquely downward from the body801. The arms803and805have apertures807and809to receive pins to pivotally mount the head32and the flipper assembly687about second horizontal axis33at the distal end658of the fifth telescopic stick20(seeFIG. 1). Referring toFIG. 1, the brick laying and adhesive applying head32articulates about horizontal axis33substantially parallel to the articulation axis16of the first stick15and the articulation axis13of the first boom12. The pose of the brick laying and adhesive applying head32is controlled by movement of a ram35.

Referring toFIG. 62, the articulated brick laying and adhesive applying head32supports a brick laying head comprising a spherical geometry robot36. The spherical geometry robot36has a linearly extendable arm40with a brick laying clamp in the form of a gripper44fitted at the lower end thereof. Referring toFIG. 1, the spherical geometry robot36has the following arrangement of joints: arm mount-roll angle37, arm mount-pitch angle38, arm sliding (arm length or linear extension)39, wrist pitch angle41, wrist roll angle42, gripper yaw angle43and with gripper44fitted to rotate about yaw axis45. This configuration provides pole free motion within the working envelope.

Referring toFIGS. 62 and 83, to achieve the arm mount-roll angle37adjustment, the body801supports a servo motor810with a belt driving a bearing reducer812connected to the base811of a clevis813, the base being rotatable relative to the body801about a horizontal axis which runs normal to the clevis813axis. To achieve the arm mount-pitch angle38adjustment, the clevis813supports about its axis814a servo motor816attached to the body801driving via a belt a bearing reducer818connected to a base815for the arm40.

The arm40has linear guides820which co-operate with bearing cars822(seeFIG. 84) on the base815to guide linear extension of the arm relative to the mount, to allow the arm40to move in a direction (typically straight up and down, but this depends on the pose) normal to the axis814of the clevis813to provide sliding movement of the arm40. This linear extension of the arm is controlled by a servo motor823attached to the base815with reduction drive pulleys connected by a toothed belt825driving a pinion827engaging a rack829located extending along the arm40.

The brick laying clamp/gripper44mounts for controlled rotation by a servo motor830driving a bearing reducer831about an axis normal and perpendicular to the plane of its jaws833,835and bearing reducer on a clevis817to provide the gripper yaw angle43adjustment; a universal joint formed by mechanism819comprising servo motor837and bearing reducer839connected by toothed belt841and pulleys provides wrist pitch angle41adjustment; and mechanism821comprising servo motor843and bearing reducer845driven by toothed belt847and pulleys provides wrist roll angle42adjustment (shown inFIG. 1). Details of these servo motors and drives can be seen inFIG. 85.

The brick laying and adhesive applying head32supports a hook151that can be used to lift items such as windows, doors, lintels and other items not shown.

Refer toFIG. 12andFIG. 13. The brick laying and adhesive applying head32supports machine vision cameras127,128mounted to view both sides of the brick126shown schematically inFIG. 13.

The jaws835,833of the laying head gripper44are independently movable by independent lead screws849,851, engaged with nuts853,855connected with the jaws835,833, and moveable by servo motors857,859, via drive belts861,863respectively. This allows the offset gripping of a brick. The arrangements for moving the jaws835,833use lead screws849,851and co-operating nuts853,855, driven by separate servo motors857,859, respectively, similar to that as described for other grippers utilised elsewhere in the embodiment, apart from the drives for the jaws being separate in order to allow independent movement of the jaws.

As can be seen inFIG. 62, when considered withFIG. 71, the straight guide784of the adhesive applicator assembly777, into which the sliding chain114may be retracted, is mounted in the body801of the brick laying and adhesive applying head32, behind the servo motor with bearing reducer that connects to clevis813. The curved guide113of the adhesive applicator assembly777descends/depends downwardly obliquely, substantially following the extent of the arms803and805for a short distance, before curving toward horizontal so that the sliding chain is presented extending substantially level, subject to the alignment of the brick laying and adhesive applying head32as controlled by the ram35, and presented above where the flipper assembly687holds the brick. With this arrangement, the adhesive applicator assembly777is kept clear of positions through which arm40and gripper44of the spherical geometry robot36could be required to move.

Tracker and Slab Scan

Referring toFIGS. 1, 12, 62, the top of the brick laying and adhesive applying head32supports a tracker component130. The tracker component130may be a Leica T-Mac or an API STS (Smart Track Sensor). Alternately tracker component130may be a single SMR (Spherical Mount Reflector) or corner cube reflector, or two or three SMRs or corner cube reflectors or a Nikon iGPS or any other suitable tracking device. Preferably the tracker component130provides real time 6 degrees of freedom position and orientation data at a rate of preferably greater than 10 kHz, or preferably 1000 Hz to 10 kHz, or preferably at a rate of 500 Hz to 1000 Hz or preferably a rate of 300 Hz to 500 Hz or 100 Hz to 300 Hz or 50 Hz to 100 Hz or 10 Hz to 50 Hz. The laying arm40and or the gripper44of the laying arm40may support a second or third tracker component131,132of the same or different type to the first tracker component130.

Referring toFIG. 3, a tracker component133or components,133,134,135are set up on the ground adjacent to the concrete slab136or on a nearby structure. The tracker component130on the laying head references its position relative to the tracker component133or components133,134,135set up on the ground or structure.

Referring toFIG. 12, the brick laying and adhesive applying head32supports a camera137that views the ground, slab136or structure or objects below it. The brick laying and adhesive applying head32is provided with laser or light projectors138that project dots or lines139onto the ground, footings, slab136or objects below it. Machine vision is used to determine the 3D shape of the ground, footings, slab136or objects below the laying head. Alternatively, the brick laying and adhesive applying head32is fitted with a laser scanner140. After positioning the truck and unfolding the boom, the brick laying and adhesive applying head32is moved around by moving the boom and stick assembly141so that the brick laying and adhesive applying head32is optionally moved around the edge of the slab136and optionally above all positions that will be built upon. The machine vision system143or scanner140scans the slab136and the areas to be built on to firstly align the slab136, machine2and working coordinate systems to their correct locations and secondly to quality check the slab136and check its flatness and level. If the slab136is not flat or level within tolerance the first course of bricks or selected bricks not shown can be individually machined by the router module47(prior to being transported to the tower10and boom and stick assembly141) to correct the out of level, flatness or height. Optionally a brick may have a groove or notch or pocket machined in it to avoid a bump or defect or object (such as a pipe projecting through the slab) on the slab136.

As the brick laying and adhesive applying head32lays a brick144, the machine vision143or laser scanner140is used to measure the laid brick144so that the height of the laid brick144is stored and later used to adjust the laying height of the dependant bricks that are laid on top of it on the next course. If the height is over tolerance, the dependant bricks above it can be machined to a reduced thickness by the router47.

The concrete slab136may alternatively be a slab of earth, rock, wood, plastic or other material or a steel deck or footings. The slab136may be on the ground or suspended.

FIG. 14shows a side view of a slab136with a first course163of a plurality of bricks159,160,161,162,163. The slab136may not be flat and in the example ofFIG. 14has a hump164. To obtain a flat top165of the first course163, the bricks,159, are machined by the router module47or cut to height with the saw46, prior to being transported to the tower10and boom and stick assembly141.

The bricks are normally fired clay but may be concrete, aerated concrete, plastic, foam, wood, compressed wood, recycled material or any block or brick shaped component or any interlocking component or a random shaped component such as rock or stone or a sculpted or moulded complex object. For applications where the supplied dimensions or shape of the bricks, blocks or objects to be laid vary significantly from the design dimensions, additional routers or saws may be added to the machine so that routing or sawing of the bricks, blocks or objects can occur simultaneously on a number of bricks, blocks or objects in parallel.

Block Moulding

In a further variation of the machine not shown but described here, the machine is provided with an on board brick or block moulding machine. A filler mixture of for example sand, clay, aggregate stone or wood chip or wood fibre is supplied to a hopper. The hopper may then optionally supply the filler mixture to a mixer which may add a binder material such as cement or polymer adhesive or water or a thermoplastic powder or fiber. The mixer then supplies the mixed filler and binder to a brick moulding press. Optionally the moulded bricks may pass through a curing station which may apply a chemical curing agent or heat or radiation. The curing station may apply steam to rapidly cure a concrete binder. Alternatively, the curing station may apply UV light to cure a UV sensitive binder resin. Alternatively, the curing station may apply moisture to cure a moisture curing polyurethane binder material. Alternatively, the curing station may apply heat to cure an epoxy binder. The moulded bricks may then be used by the automated brick laying machine. Alternatively, the filler mixture may contain a thermoplastic material such as recycled plastic. When pressed under heat the plastic binder melts, fusing the sand or aggregate or wood fiber material when it cools. Brick or block making presses are commercially available from suppliers such as Besser.

Harsh Environment

In an adaptation of the machine, with radiation protection, the machine could be used for erecting containment structures in nuclear disaster zones.

In a further adaptation of the machine, the machine may be adapted to work in a low pressure atmosphere or in a vacuum and in the presence of ionising radiation. In this format with an integral automated brick or block making unit, the machine could be used for building structures on the moon or Mars or in other extra-terrestrial locations.

Advantages of the Invention

The invention provides an improved automated brick laying machine that is compact and mobile and able to drive on public roads. The arrangement and configuration of components allows the machine to have a very large working envelope whilst also being compact for road travel. It is capable of receiving packs of bricks and processes them to in effect 3D print a full size structure of walls. The machine is electronically programmed and can build a wide variety of structures.

The invention uses thin bed mortars or liquid adhesives which need not support the weight of a brick so can be very fluid and may contain no particulates or may contain very fine non-abrasive particulates, rather than abrasive sand which is used in thick bed mortars used in traditional manual brick-laying. Given variations in slab height, the desire to completely remove the need for a thick bed of mortar or thick adhesive between the slab and the first course of bricks requires a very level slab, level within a few mm of height tolerance. To achieve the slab height tolerance required for use of thin be mortars would incur significant additional cost from concrete contractors. The provision of a router module in the invention allows bricks to be pre-machined based on measured slab elevation at the required brick location, which results in only a slight increase in build time, to machine in the router, each brick in the first course, so that the top of the first course is laid at the correct height and level, even on inaccurate slabs. Deviations of between 0 and 50 mm of flatness and level can be easily accommodated. Larger deviations could be accommodated if required.

To build common house size structures, the boom needs to reach out 30 m. To manoeuvre on suburban roads a short truck is advantageous. To fit on small building sites a compact machine is advantageous. Bricks being conveyed along a boom, must be restrained, so that they can't fall and damage structures or injure personnel. By conveying the bricks along the inside of the boom, the cross section of the boom can be made smaller than the total cross section of a boom with external guarding to contain externally conveyed bricks. The smaller boom cross section enables a smaller and more compact machine to be built. The present invention has cable chains routed inside the boom. By conveying the bricks internally, and routing the services internally, the structural cross section of the boom is maximised for a given over all cross section, thereby increasing the stiffness of the boom which reduces the dynamic displacement of the boom. A light weight boom is also possible due to the large cross section.

The present invention utilises a series of shuttles that transfer a brick from one shuttle to the next. This system has the advantage that the movement of bricks along the boom is completely independent of the brick preparation or laying processes. In this way, the laying rate can be kept as high as possible. Both the brick preparation, the brick transport and the laying process can proceed at the individual maximum rates, limited only by the availability of the bricks into each process, and the availability of a consumer process for the output of the bricks.

The invention is intended to build all of the external and internal walls of a structure. Whilst it would be possible for the invention to build only some of the brick walls in a structure, with the remaining walls being manually constructed later with manually laid bricks or manually placed stud walls or precast panels, it should be understood that the invention allows the rapid and accurate placement of bricks and construction of brick walls faster and at a cost equal to or lower than the cost of manually built walls using bricks or stud framing or pre cast concrete.

It should be appreciated that the scope of the invention is not limited to the particular embodiment described herein, and the skilled addressee will understand that changes can be made without departing from the spirit and scope of the invention.