Construction system

A construction system is provided. The construction system includes at least one machine. The construction system also includes a gantry system having a beam member. The construction system further includes a reference member provided proximal to a predetermined path of the at least one machine. The construction system includes a sensing unit associated with the at least one machine. The sensing unit is configured to determine distance of a portion of the at least one machine from the reference member. The construction system also includes a control unit in communication with the at least one machine and the sensing unit. The control unit is configured to receive inputs indicative of distance of the portion of the at least one machine from the reference member. The control unit is also configured to move the at least one machine to move the gantry system along the reference member for a predetermined distance.

TECHNICAL FIELD

The present disclosure relates to a construction system and more particularly to a construction system and a method of operating the construction system.

BACKGROUND

A gantry system is used for constructing structures, such as buildings, towers, etc. Typically, the gantry system includes a pair of rails, a beam member, and a dispensing system. The pair of rails, being positioned on a ground surface, is stationary and the beam member extends between the pair of rails. The dispensing system is movable on the beam member. Typically, the pair of rails and the beam member remain stationary with respect to the ground surface, while a control unit controls the movement of the dispensing system on the beam member. As per the required movement, the dispensing system dispenses material to build the structures. As such, the gantry system requires considerable time to set up, as the pair of rails and the beam member are required to be installed at a site where construction of the structures is desired. Further, such setting up of the gantry system requires skilled personnel, thereby involving additional time and cost.

U.S. Patent Publication Number 2015/0045992 discloses a robotic control system for a vehicle having a chassis and a drive system. The robotic control system includes a control unit configured to control the drive system. The control unit is further configured to do at least one of the following activities, such as auto-loading the vehicle onto a trailer, precluding tipping of the vehicle, stabilizing yaw of the vehicle, simulating Ackerman steering, balancing the vehicle on two wheels, retrieving an other vehicle, transferring a payload from the vehicle to the other vehicle, coupling of at least one other vehicle to the vehicle, retrieving or moving a container using either relative sensing or absolute position referencing, and profile cutting of plants and 3D print cement.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a construction system is provided. The construction system includes at least one machine. The construction system also includes a gantry system having a beam member. The beam member is supported at a first end on the at least one machine. The construction system further includes a reference member provided proximal to a predetermined path of the at least one machine. The construction system includes a sensing unit associated with the at least one machine. The sensing unit is configured to determine distance of a portion of the at least one machine from the reference member. The construction system also includes a control unit in communication with the at least one machine and the sensing unit. The control unit is configured to receive inputs indicative of distance of the portion of the at least one machine from the reference member. The control unit is also configured to move the at least one machine to move the gantry system along the reference member for a predetermined distance.

In one aspect of the present disclosure, a method of operating a construction system is provided. The construction system includes at least one machine supporting a gantry system. The method includes determining distance of a portion of the at least one machine from a reference member. The method also includes moving the at least one machine to move the gantry system along the reference member for a predetermined distance.

In yet another aspect of the present disclosure, a method of operating a construction system is provided. The construction system includes at least one machine supporting a gantry system. The method includes determining distance of a first portion of the at least one machine from a reference member. The method also includes determining distance of a second portion of the at least one machine from a reference member. The method further includes comparing the distance of the second portion of the at least one machine from the reference member and the distance of the first portion of the machine from the reference member. The method includes moving the at least one machine to move the gantry system, along the reference member for a predetermined distance. The method also includes steering the at least one machine upon determining a predefined deviation between the distance of the second portion of the at least one machine from the reference member and the distance of the first portion of the machine from the reference member.

DETAILED DESCRIPTION

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.FIG. 1is a perspective view of an exemplary construction system100, according to one embodiment of the present disclosure. The construction system100includes at least one machine, such as a machine102. The machine102may include or be part of a mobile vehicle. For example, the machine102may include, but is not limited to, track type loaders, multi-terrain loaders, compact track loaders, mining shovels, wheel loaders, back hoe loaders, motor graders, track type tractors, wheeled tractors, pavers, excavators, material handlers, forestry machines, or any other type of machine, mobile or stationary. For simplicity purposes, the machine102is shown and described as a skid steer loader.

The machine102includes a body104having upright stanchions or tower portions (not shown) on a left side and a right side of the machine102, and an operator station108. A roof110of the machine102is defined on top of the operator station108of the machine102. Further, the machine102includes drive wheels112that are mounted to the body104and are powered by a power source (not shown), such as an engine (not shown) of the machine102. The engine is mounted to the body104rearward of the operator station108in an engine enclosure (not shown).

The drive wheels112are driven in a manner traditionally known in the art. However, in an alternative embodiment, the drive wheels112may be replaced by left and right endless belts or track assemblies (not shown), or any other type of drive system known in the art. For example, the machine102may be embodied as a tracked machine. The machine102includes a linkage assembly114. The linkage assembly114includes lift arms116pivotably mounted on the left and right side of the body104. The machine102may also include a work implement (not shown), such as a bucket, pivotally mounted at a front end of the lift arms116.

The construction system100includes a gantry system120. In one example, the gantry system120is a Three Dimensional (3D) construction gantry system. The gantry system120includes a beam member122. The beam member122includes a first end124and a second end126. The first end124of the beam member122is supported on the machine102. More particularly, the first end124of the beam member122may be supported by the linkage assembly114, the work implement, or the roof110of the machine102. In the embodiment illustrated inFIG. 1, the first end124of the beam member122is supported on the roof110of the machine102.

The gantry system120includes a first coupler128. The first coupler128removably couples the first end124of the beam member122with the linkage assembly114. The first coupler128may be embodied as a pillar structure. The first coupler128extends along a first axis X-X′. It should be noted that a height of the beam member122of the gantry system120may remain fixed during formation of one construction layer at a construction site, and may be changed during formation of a subsequent construction layer. In another example, the work implement may be moved to dynamically adjust the height of the beam member122during the formation of a single layer at the construction site.

The construction system100also includes an auxiliary machine134. The auxiliary machine134supports the second end126of the beam member122. The auxiliary machine134moves with the machine102. In one example, the auxiliary machine134is embodied as an A-frame support136movable on a set of wheels137. The A-frame support136may be made of a metal or a non-metal, based on system requirements. A weight of the A-frame support136is decided based on a weight and dimensions of the beam member122. The machine102and the A-frame support136together support either ends124,126of the beam member122so that the beam member122remains horizontal in operation.

It should be noted that the second end126of the beam member122may be supported by any another auxiliary machine apart from the A-frame support136, without limiting the scope of the present disclosure. In another embodiment illustrated inFIG. 3, a second end226of a beam member222may be supported by a second machine204. In such an embodiment, the construction system200includes a first machine202(as the machine102) and a second machine204. The first machine202and the second machine204may be similar or different from each other. In one example, the first and second machines202,204may be similar to the machine102shown inFIG. 1. Accordingly, the first and second machines202,204may include a skid steer loader. Alternatively, the first and second machines202,204may embody any other wheeled or tracked machine known in the art.

In another embodiment, the construction system100may only include one machine102which supports the gantry system130. Specifically, in this embodiment, the first end124of the beam member122is supported by the machine102. In case the gantry system130is short for example of two or three feet like a wall builder, the gantry system130may be supported on the machine102, and can be configured to move along a straight or limited undulated path.

In the illustrated embodiment, the first coupler232removably couples a first end224of the beam member222with lift arms216of a linkage assembly214of the first machine202. Further, a second coupler234removably couples the second end226of the beam member222with lift arms218of a linkage assembly215of the second machine204. In another example, the first and second coupler232,234may be removably coupled to the work implement or roof210,212of the first and second machines202,204, respectively, without limiting the scope of the present disclosure.

Referring again toFIG. 1, the gantry system120includes a dispensing system130. The dispensing system130is adapted to dispense construction material during a construction event, for example construction of a wall. The dispensing system130is coupled to the beam member122. The dispensing system130is movable along a length “L” of the beam member122and along a Y-Y′ axis. In one example, the dispensing system130is embodied as an extruder. The dispensing system130may embody any known system/equipment that allows dispensing of the construction material. For the 3D construction gantry system, the dispensing system130may be embodied as a print head.

Further, the dispensing system130may be movable along the first axis X-X′ with respect to the beam member122of the gantry system120. More particularly, the dispensing system130may be moved about the first axis X-X′ as per requirements for formation of various construction layers. The dispensing system130may be powered and operated by a hydraulic system or a pneumatic system or an electrical system of the machine102. Further, the hydraulic, electric and/or pneumatic system of the machine102may also be utilized to move the dispensing system130along the first axis X-X′ and along the length “L” of the beam member122.

The construction system100further includes a set of limiting members, such as a first limiting member138and a second limiting member140, provided proximal to a predetermined path of the machine102. The first and second limiting members138,140are spaced apart from each other. In one example, the first and second limiting members138,140are positioned parallel to each other. In the illustrated embodiment, the first and second limiting members138,140are embodied as rectangular shaped plates. However, the first and second limiting members138,140may be embodied as square shaped plates. In another example, the first and second limiting members138,140may be embodied as poles, walls or any other upstanding structure.

The construction system100also includes a reference member142. The reference member142is provided proximal to the predetermined path of the machine102. The profile of the reference member142may be dependent upon the predetermined path of the machine102. More particularly, the reference member142is provided along a wall of a structure to be constructed by the construction system100. The reference member142extends between the first and second limiting members138,140. In the illustrated example, the reference member142is perpendicular to each of the first and second limiting members138,140. Alternatively, the reference member142may be curved, inclined or angled with respect to the first and second limiting members138,140.

In the illustrated embodiment, the reference member142is embodied as a rectangular plate member. The rectangular plate member may be made of a metal or a non-metal, without any limitations. In another example, the reference member142may be embodied as a longitudinal upstanding member or a string coupled to each of the limiting members138,140at either ends. Further, the string may be made of a metal or a non-metal. For example, the string may embody a metal wire, a nylon rope, and the like. In an example, the reference member142may be composed of wooden boards which are two inches thick, four inches tall, and the length could be eight feet or longer. The wooden boards may be attached to multiple stakes pounded in the ground.

Referring now toFIGS. 1, 2 and 4, the construction system100includes a sensing unit144communicably associated with the at least one machine e.g. the machine102. The sensing unit144is adapted to determine a distance between one or more portions of the machine102and the reference member142. In an example, the sensing unit144is adapted to determine a distance between at least two distant portions of the machine102, for example two distant portion on a side portion145of the machine102which is proximate to the reference member142. The sensing unit144includes a plurality of sensors, such as, a first sensor146and a second sensor148. The first and second sensors146,148are mounted on a panel156. The panel156is in turn coupled to the side portion145of the machine102. The panel156may embody a rectangular bar member made of a metal or a non-metal. In alternative embodiments, the panel156may mounted on any other portion of the machine102facing the reference member142. Alternatively, the plurality of sensors, such as the first sensor146and the second sensor148, may be mounted directly on the machine102. In such a case the distance between the first sensor146and the second sensor148, may be accordingly calibrated. Further in such a case the distance between the first sensor146and the second sensor148with respect to the reference member142may be also be accordingly calibrated.

The first sensor146is positioned at a first portion150of the machine102. The first sensor146generates a first input indicative of a first distance (D1) between the first portion150of the machine102and the reference member142. Further, the second sensor148is positioned at a second portion152of the machine102. The second portion152is distant from the first portion150of the machine102. The second sensor148generates a second input indicative of a second distance (D2) between the second portion152of the machine102and the reference member142.

The first and second sensors146,148may include any one or a combination of sonic sensors, laser sensors, contact sensors, and the like. In one example, the first and second sensors146,148may include proximity sensor. It should be noted that the first and second sensors146,148may include any other type of sensor that is capable of generating signals indicative of the distance between the first portion150of the machine102and the reference member142and/or the second portion152of the machine102and the reference member142. It should also be noted that additional sensors can be added to increase the control of the system100. These sensors can determine distance to the reference member142, the limiting members138and140.

The construction system100includes a control unit154(seeFIG. 2). The control unit154is in communication with the machine102. In one example, the control unit154is in communication with a steering unit (not shown) of the machine102, and is therefore configured to steer the machine102, as and when required. Further, the control unit154is also in communication with the first and second sensors146,148of the sensing unit144to continuously receive first and second inputs indicative of the first distance (D1) and the second distance (D2) from the first sensor146and the second sensor148, respectively. The control unit154is also configured to determine a direction of movement of the machine102.

The control unit154is configured to compare the first and second inputs indicative of the first distance (D1) and the second distance (D2). The control unit154further generates an input indicative of a change in the first or second distances between the first or second portions150,152of the machine102and the reference member142, when the machine102is moving in a direction of travel “D”. The control unit154also generates inputs to move the machine102and accordingly move the gantry system120along the reference member142for a predetermined distance. Therefore, as long as the first distance (D1) is equal to the second distance (D2), the control unit154continues to generate inputs to allow movement of the machine102along the reference member142for the predetermined distance.

Further, the control unit154, upon determining that the first distance (D1) has decreased from with respect to the second distance (D2) (i.e. D1<D2), may compare the difference between the first distance (D1) and the second distance (D2) to determine a difference value. The control unit154may thereafter compare the difference value with a threshold change of distance between the first or second portions150,152of the machine102and the reference member142. The threshold change of distance may be defined as a change of distance below which steering of the machine102is undesired, and beyond which steering of the machine102will be desired. In an example, the threshold change of distance may be 0.01 millimeter. In such an example, when the control unit154determines that the distance between the portion150of the machine102and the reference member142is below the threshold change of distance of 0.01 millimeter, the control unit154may continue to generate inputs to move the machine102and accordingly move the gantry system120along the reference member142for the predetermined distance.

However, when the control unit154determines that the difference value is above the threshold change of distance, the control unit154may generate an input indicative of change in distance of the portion150of the machine102and the reference member142. Thereafter, the control unit154may steer the machine102in a first direction i.e. away from the reference member142, based on the input indicative of the change in distance. In such a case, the control unit154may steer the machine102in the first direction so that the first distance (D1) becomes equal to the second distance (D2) (i.e. D1=D2). Likewise, the control unit154, upon determining that the first distance (D1) has increased with respect to the second distance (D2) (i.e. D1>D2), steers the machine102in direction opposite to the first direction, i.e. towards the reference member142. Again, in such a case, the control unit154may steer the machine102in the direction opposite to the first direction so that the first distance (D1) becomes equal to the second distance (D2) (i.e. D1=D2).

More specifically, in one example, where the direction of travel “D” corresponds to a forward direction of the machine102, the control unit154receives the first input indicative of the first distance (D1), from the first sensor146. Further, the control unit154generates the input indicative of the change in the first distance (D1). The input is generated based on a comparison between the first distance (D1) and the second distance (D2).

In another example, the direction of travel “D” may correspond to the reverse direction of the machine102. In such an example, the control unit154receives the second input indicative of the second distance (D2) from the second sensor148and generates the input based on a comparison between the second distance (D2) and the first distance (D1). Further, the control unit154, upon determining that the second distance (D2) has decreased from with respect to first distance (D1) (i.e. D2<D1), steers the machine102in direction opposite to the first direction i.e. towards the reference member142, so that the second distance (D2) becomes equal to the first distance (D1) (i.e. D2=D1). Likewise, the control unit154, upon determining that the second distance (D2) has increased from the first distance (D1) (i.e. D2>D1), steers the machine102in a first direction i.e. away from the reference member142, so that the second distance (D2) becomes equal to the first distance (D1) (i.e. D2=D1.

The control unit154is further adapted to determine a distance of the first or second portions150,152of the machine102from the first and second limiting members138,140, respectively. More particularly, when the machine102is moving in the forward direction, the control unit154determines a distance between the first portion150of the machine102and the first limiting member138. Further, when the machine102is moving in the reverse direction, the control unit154determines a distance between the second portion152of the machine102and the second limiting member140. The control unit154compares the distance between the first portion150or the second portion152and the corresponding first limiting member138or the second limiting member140of the machine102with a predefined threshold. In a situation where the distance between the first portion150or the second portion152and the corresponding first limiting member138or the second limiting member140of the machine102is below a predefined threshold, the control unit154restricts the movement of the machine102in the forward or reverse directions, respectively.

In one exemplary embodiment, the control unit154determines a distance travelled by the machine102in the forward or reverse directions. The control unit154may receive inputs from one or more sensors present onboard the machine102to determine the distance travelled by the machine102. Further, the control unit154compares the distance travelled by the machine102with a predefined distance. The predefined distance corresponds to the distance to be covered by the machine102during a single construction event in the forward or reverse directions. The control unit154restricts the movement of the machine102along the reference member142upon determining that the distance travelled by the machine102is equal to the predefined distance.

INDUSTRIAL APPLICABILITY

The present disclosure relates to a system and method for controlling the construction system100,200.FIG. 6is a flowchart for a method500of operating a construction system, such as the construction system100or the construction system200. The construction system may include at least one machine, such as the machine102,202, or204, supporting the gantry system130. At step502, the method500includes determining distance of a portion of the at least one machine from a reference member142. At step504, the method500includes moving the at least one machine, such as the machine102,202, or204, to move the gantry system130along the reference member142for the predetermined distance.

FIG. 7is another flowchart for a method600of operating a construction system, such as the construction system100or the construction system200. The construction system100may include at least one machine such as the machine102,202, or204, supporting the gantry system130. The method600initiates with the commencement of operation of the machine102. At step602, the method600includes determining distance of a portion such as a first portion150of the at least one machine from the reference member142. At step604, the method600includes determining distance of a second portion152of the at least one machine from the reference member142. At step606, the method600includes comparing the distance of the second portion152of the at least one machine from the reference member142and the distance of the first portion150of the machine102from the reference member142. At step608, the method600includes moving the at least one machine to move the gantry system130, along the reference member142for the predetermined distance. Further, the method600, at step610includes steering the at least one machine upon determining a predefined difference between the distance of the second portion of the at least one machine from the reference member142and the distance of the first portion of the machine from the reference member142.

The construction system100,200of the present disclosure provides a simple and cost effective solution to control the movement of at least one machine such as the machine102,202, or204associated with the construction system100,200. Since the construction system100,200of the present disclosure is simple and easy to install, the construction system100,200may be conveniently and quickly installed in different locations as per requirement. The construction system100,200makes use of low cost sensors for controlling the movement of the machine102,202,204. The construction system100,200of the present disclosure follows a set of instructions stored in the control unit154and moves the at least one machine102and associated gantry system120, dispensing system130to complete the construction of the 3D structure in a layer by layer fashion as per the set of instructions stored in the control unit154.