Systems and methods for automated building construction

The disclosed systems for automated building construction may include upright supports, a support platform coupled to and vertically movable relative to the upright supports, and a bridge platform coupled to and horizontally movable along the support platform. A track may be mounted on the bridge platform, and a robotic arm may be coupled to and movable along the track. The robotic arm may be configured to retrieve structural insulated panels and to position the structural insulated panels to construct at least a portion of a building. Various other related systems and methods are also disclosed.

BACKGROUND

In recent years, certain automated building construction techniques been developed for the construction industry. For example, there are systems that extrude cement in layers in a predetermined pattern to form walls of a building. These systems are essentially large three-dimensional printers. However, these conventional systems are often limited in the types, shapes, and sizes of buildings that may be constructed.

DETAILED DESCRIPTION

The present disclosure includes systems and methods for automated building construction. The disclosed systems may include a support platform that may be configured to move vertically along upright supports and a bridge platform that may be configured to move horizontally along the support platform. A track may be mounted on at least the bridge platform. A robotic arm may be coupled to and movable along the track. The robotic arm may be configured to retrieve structural insulated panels (“SIPs”) and to position the structural insulated panels to construct at least a portion of a building.

The following will provide, with reference toFIG.1, detailed descriptions of a system for automated building construction. With reference toFIG.2, the following will provide detailed descriptions of an example structural insulated panel that may be used for automated building construction. With reference toFIGS.3-5, the following will provide detailed descriptions of a system for automated building construction at various stages of construction. With reference toFIG.6, the following will provide detailed descriptions of an example method of constructing a building.

FIG.1is a perspective view of a system100for automated building construction, according to at least one embodiment of the present disclosure. The system100may include upright supports102positioned adjacent to a construction site104where at least a portion of a building (e.g., a house, a shed, a classroom, etc.) is to be constructed. For example, four upright supports102A,102B,102C, and102D may be positioned at respective corners of the construction site104. At least one support platform106may be coupled to the upright supports102. For example, a first support platform106A may be positioned to extend between the first upright support102A and the second upright support102B, and a second support platform106B may be positioned to extend between the third upright support102C and the fourth upright support102D. The support platform(s)106may be vertically movable relative to the upright supports102.

In some examples, relational terms, such as “first,” “second,” etc., may be used for clarity and convenience in understanding the disclosure and accompanying drawings and do not connote or depend on any specific preference, orientation, or order, except where the context clearly indicates otherwise.

The system100may also include a bridge platform108coupled to the support platform(s)106. The bridge platform108may be horizontally movable along the support platform(s)106, such as along guiderails110of the support platform(s)106. For example, the bridge platform108may be suspended between the first support platform106A and the second support platform106B.

Optionally, a cross platform112may also be coupled to the support platform(s)106. In some embodiments, the cross platform112may be stationary relative to the support platform(s)106. In additional embodiments, the cross platform112may also be horizontally movable along the support platform(s)106, such as along the guiderails110.

A track114may be mounted on at least the bridge platform108. In some embodiments, as shown inFIG.1, the track114may also be mounted on the support platform(s)106and the cross platform112. The track114may form a loop when the bridge platform108and/or the cross platform112are in an initial, home position (as illustrated inFIG.1). For example, a first track segment114A may be mounted on the bridge platform108, a second track segment114B may be mounted on the first support platform106A, a third track segment114C may be mounted on the cross platform112, and a fourth track segment114D may be mounted on the second support platform106B. The track114may be a monorail track or a dual rail track.

As illustrated inFIG.1, the track114may be mounted to a top of the bridge platform108, support platforms106, and cross platform112. However, the present disclosure is not limited to this arrangement. In additional embodiments, the track114may be mounted on a side (e.g., the inside) or a bottom of the platforms108,106,112.

The system100may also include a robotic arm116, which may be coupled to and movable along the track114. The robotic arm116may be configured to retrieve building materials including structural insulated panels118(“SIPs”), such as from a stack120of the SIPs118, and to position the SIPs118to construct at least a portion of a building. The robotic arm116may also be configured to retrieve additional building materials, such as doors, window sections122, structural supports124, screws, bolts, nails, brackets, trusses, roof sections, etc. These building materials may be positioned for retrieval by the robotic arm116outside of an outer periphery126defined by the upright supports102, within a building envelope128in which the building is to be constructed, on the support platform(s)106, on the bridge platform108, on the cross platform112, or any combination thereof.

In some examples, the robotic arm116may be a six-axis robotic arm116, which may be capable of moving an end effector thereof in six degrees of freedom (e.g., x-direction, y-direction, z-direction, yaw, pitch, and roll). The end effector of the robotic arm116may include elements and features for constructing the building. For example, the end effector may include a suction element, grasper, or magnet for lifting the SIPs118and/or other building materials. The end effector may include a screwdriver head for driving bolts or screws for joining portions of the building under construction. The end effector may include a nail gun for driving nails for joining portions of the building under construction.

In some examples, the construction site104may initially include a preformed foundation (e.g., cement foundation, wooden foundation, stone foundation, etc.) upon which the building is to be constructed.

The system100may be mobile and configured for assembly at any suitable construction site104. For example, the upright supports102may include wheels130or similar elements that may be used for moving the upright supports102into a position adjacent to the construction site104. When the upright supports102are in their proper position, the upright supports102may be secured in place. For example, one or more outriggers132may be deployed to secure the upright supports to a ground surface at the construction site104. The upright supports102may be or include an I-beam, an upright truss beam, and/or any other suitable structure. Similarly, the support platform(s)106, bridge platform108, and/or the cross platform112may be or include an I-beam, a support truss beam, and/or any other suitable structure. In some examples, the upright supports102, support platform(s)106, bridge platform108, and/or cross platform112may respectively include multiple segments that are coupled to each other in an end-to-end fashion. Accordingly, the system100may be modular and adaptable to construct buildings of different sizes.

The system100may include various mechanisms for moving the various components thereof relative to each other, as well as for controlling and sensing such movement. For example, a lifting mechanism134may be employed to lift the support platform(s)106vertically along the upright supports102, such as along lift rails136mounted to the upright supports102. The lifting mechanism134may be positioned on the upright supports102, on the support platform(s)106, or a combination thereof. A bridge movement mechanism138may be employed to move the bridge platform108horizontally along the support platform(s)106. A drive mechanism140may be employed to move the robotic arm116along the track114. A stop mechanism142may be employed to lock the robotic arm116in position along the track114. A position sensor144may be employed to locate the robotic arm116relative to the bridge platform108, support platform(s)106, cross platform112, the track114, the stack120of SIPs118or other building material, a ground surface, portions of the building to be constructed, etc.

In some embodiments, the system100may also include a hoist146that may be positioned to lift building components (e.g., SIPs118, structural supports124, etc.), such as to move the building components within the building envelope128. For example, the hoist146may be positioned on a lower side of the bridge platform108, such that the hoist146can be moved into a desired location over the building envelope128. The hoist146may be movable along a length of the bridge platform108.

The lifting mechanism134, bridge movement mechanism138, and drive mechanism140may each include any suitable mechanism for moving the respective components of the system100relative to each other. By way of example and not limitation, each of these mechanisms134,138,140may include a stepper motor, a servo motor, a pulley system, a gear train, a roller, a rack and pinion, a linear actuator, or any combination thereof.

The stop mechanism142may include any suitable mechanism for stopping the robotic arm116(e.g., a base of the robotic arm116) relative to the track114. By way of example and not limitation, the stop mechanism142may include a linear actuator (e.g., a pneumatic pin), a lever arm, a cam, a brake pad, or any combination thereof. In some examples, the track114may include engagement elements (e.g., holes, teeth, depressions, etc.) with which the stop mechanism142may engage to lock the robotic arm116in place, as desired.

The position sensor144may include any suitable sensor for determining the position of the robotic arm116. By way of example and not limitation, the position sensor144may include an optical sensor (e.g., a laser emitter and sensor, an area scanner, an infrared emitter and sensor, a visible light sensor, etc.), a Hall effect sensor, a proximity switch, an encoder, or any combination thereof.

As noted above, the robotic arm116may be configured to retrieve and position SIPs118to construct at least a portion of a building.FIG.2is a perspective view of an SIP200, according to at least one embodiment of the present disclosure. The SIP200may include a first panel202, a second panel204, and an insulation material206positioned between the first panel202and the second panel204.

The first and second panels202,204may be or include any rigid plate material. By way of example and not limitation, the first and second panels202,204may each include a wood material (e.g., plywood, oriented strand board, solid wood plank, etc.), a hard-plastic material, cement material, ceramic material, a metal material, or a composite material. The insulation material206may include a rigid insulation material, such as a foam material (e.g., polystyrene foam, polyisocyanurate foam, polyurethane foam, etc.) or a honeycomb material. Some SIPs200may also include a window208or door coupled to the first and/or second panels202,204. The SIPs200may be provided in a variety of sizes, such as to accommodate different designs or purposes. The SIPs200may be painted, stained, encased, or otherwise at least partially covered by a surface finish. In some examples, the SIPs200may include an engagement feature210, which may be an element with which the end effector of the robotic arm116may engage to lift and maneuver the SIPs200.

FIG.3is a plan view of a system300for automated building construction in an initial stage (e.g., a home position), according to at least one embodiment of the present disclosure. In some respects, the system300shown inFIG.3is similar to the system100described above with reference toFIG.1. For example, the system300may include upright supports302positioned adjacent to a construction site304. Support platforms306may extend between the upright supports302. A bridge platform308may be coupled to and horizontally movable along the support platforms306. A cross platform312may also be coupled to the support platforms306.

A track314may be mounted to at least the bridge platform308. For example, a first track segment314A may be mounted to the bridge platform308, a second track segment314B may be mounted to a first support platform306A, a third track segment314C may be mounted to the cross platform312, and a fourth track segment314D may be mounted to a second support platform306B. A robotic arm316may be coupled to and movable along the track314. The robotic arm316may be configured to retrieve SIPs318(e.g., from a stack320of SIPs318) and to position the SIPs318to construct at least a portion of a building in the construction site304.

The system300may also include a lifting mechanism334configured to vertically move the support platforms306along the upright supports302, a bridge movement mechanism338configured to horizontally move the bridge platform308along the support platforms306, and a drive mechanism340configured to move the robotic arm316(e.g., a base of the robotic arm316) along the track314.

As shown inFIG.3, the support platforms306may each be formed of support platform segments307A,307B that are coupled to each other in an end-to-end fashion. Each of the support platform segments307A,307B may have a length that may facilitate transportation and assembly of the system300. By way of example and not limitation, each of the support platform segments307A,307B may have a length between about 5 feet and about 20 feet (e.g., between about 8 feet and about 10 feet).

The track314may be positioned along an inner portion (e.g., at least partially within an outer periphery of the system300defined by the upright supports302) of the support platforms306, bridge platform308, and cross platform312to facilitate constructing a building inside of these platforms306,308,312. Accordingly, the robotic arm316may also be supported on the inner portion of the platforms306,308,312as the robotic arm316moves along the track314.

Some building materials325for retrieval by the robotic arm316may be located on the bridge platform308(as shown inFIG.3), on the support platforms306, and/or on the cross platform312. For example, fasteners (e.g., bolts, screws, or nails), brackets, structural supports, and/or other building materials may be positioned on one or more of the platforms306,308,312for efficient retrieval by the robotic arm316as needed, without necessarily returning the robotic arm316and the bridge platform308to the home position.

FIG.3illustrates the system300in an initial, home position in which the bridge platform308is located at an end of the support platforms306. In this state, the first track segment314A on the bridge platform308may be aligned with the second track segment314B and the fourth track segment314D, such that the robotic arm316(e.g., a base of the robotic arm316) may move from the first track segment314A to either the second track segment314B or the fourth track segment314D. In some embodiments, an alignment mechanism346may be configured to align the first track segment314A with the second track segment314B and/or with the fourth track segment314D. For example, the alignment mechanism346may include a sensor configured to sense when the first track segment314A is aligned with the second track segment314B and/or with the fourth track segment314D. The alignment mechanism346may also include a lock configured to lock the bridge platform308in position relative to the support platforms306.

FIG.4is a plan view of the system300ofFIG.3in a first active (e.g., constructing) position, according to at least one embodiment of the present disclosure. As shown inFIG.4, in the first active position, the robotic arm316has already positioned several SIPs318to begin construction of a building348. The robotic arm316has retrieved another SIP318from the stack320of SIPs318. The robotic arm316is located on the bridge platform308to place the SIP318in an appropriate position. The bridge platform308has been horizontally moved along the support platforms306into a position where the robotic arm316can reach the appropriate location for placing the SIP318.

FIG.5is a plan view of the system ofFIG.3in a second active (e.g., constructing) position, according to at least one embodiment of the present disclosure. As shown inFIG.5, the robotic arm316has already positioned several SIPs318to begin construction of the building348. The robotic arm316has retrieved another SIP318from the stack320of SIPs318and has been moved along the track314to be positioned on one of the support platforms306. Positioning the robotic arm316on the support platform306may facilitate reaching an appropriate location for positioning the SIP318and orienting the SIP318for proper positioning.

FIG.6is a flow diagram illustrating a method600of automated building construction, according to at least one embodiment of the present disclosure. At operation610, upright supports may be positioned adjacent to a construction site. Operation610may be performed in a variety of ways. For example, the upright supports may be rolled (e.g., with wheels attached to the upright supports) into position and secured in their respective locations, such as via an outrigger. In some embodiments, multiple upright support segments may be coupled to each other end-to-end to increase a height of each of the upright supports.

At operation620, at least one support platform may be coupled to the upright supports. The at least one support platform may be vertically movable along the upright supports. Operation620may be performed in a variety of ways. For example, two support platforms may be coupled to the upright supports via lift rails. A lifting mechanism (e.g., a motor, a pulley system, a rack and pinion, etc.) may be configured to lift the support platforms along the upright supports.

At operation630, a bridge platform may be coupled to the at least one support platform such that the bridge platform is horizontally movable relative to the support platform(s). Operation630may be performed in a variety of ways. For example, the bridge platform may be mounted to one or more guiderails of the support platform(s). A bridge movement mechanism may be configured to horizontally move the bridge platform along the support platform(s).

At operation640, a robotic arm (e.g., a six-axis robotic arm) may be mounted to a track supported by the bridge platform. The robotic arm may be movable along the track. Operation640may be performed in a variety of ways. For example, the track may be supported on a top, side, or bottom of the bridge platform. A drive mechanism may be configured to move the robotic arm along the track into various positions for constructing a building (e.g., retrieving SIPs and positioning the SIPs in desired locations).

At operation650, structural insulated panels may be positioned at the construction site with the robotic arm to construct at least a portion of the building. Operation650may be performed in a variety of ways. For example, the robotic arm may be moved into a position along the track adjacent to a stack of SIPs, and an end effector of the robotic arm may lift (e.g., grasp, suction, magnetically lift, etc.) an SIP from the stack. Then, the robotic arm, as it is holding the SIP, may be moved into an appropriate location to place the SIP. The robotic arm may then orient and position the SIP in the appropriate location to construct a feature (e.g., a portion of a wall, a window, a door, etc.) of the building.

Accordingly, the present disclosure includes systems and methods for automated building construction that may include a support platform and a bridge platform that are vertically movable relative to upright supports. The bridge platform may be horizontally movable relative to the support platform. A robotic arm may be mounted on the bridge platform and movable along a track, which may be supported by the bridge platform and optionally the support platform. The robotic arm may be configured for retrieving and positioning structural insulated panels to construct a building. This system may be modular and easy to assemble and use for various construction projects.

The following example embodiments are also included in the present disclosure.

Example 1: A system for automated building construction, which may include: upright supports; a support platform coupled to the upright supports and configured to move vertically along the upright supports; a bridge platform coupled to the support platform and configured to move horizontally along the support platform; a track mounted on the bridge platform; and a robotic arm coupled to and movable along the track, wherein the robotic arm is configured to retrieve structural insulated panels and to position the structural insulated panels to construct at least a portion of a building.

Example 2: The system of Example 1, wherein the upright supports comprise wheels for moving the upright supports into a position for constructing the building.

Example 3: The system of Example 1 or Example 2, wherein the upright supports comprise four upright supports.

Example 4: The system of any of Examples 1 through 3, wherein the track is further mounted on the support platform.

Example 5: The system of any of Examples 1 through 4, wherein the track comprises a first track segment mounted on the bridge platform and a second track segment mounted on the support platform, wherein the first track segment and the second track segment are configured to be aligned with each other when the bridge platform is in a home position.

Example 6: The system of any of Examples 1 through 5, wherein at least a portion of the track is positioned inside an outer periphery defined by the upright supports.

Example 7: The system of any of Examples 1 through 6, wherein the robotic arm comprises a six-axis robotic arm.

Example 8: The system of any of Examples 1 through 7, wherein the bridge platform comprises at least one bridge truss beam.

Example 9: The system of any of Examples 1 through 8, wherein the support platform comprises at least one support truss beam.

Example 10: The system of any of Examples 1 through 9, wherein each of the upright supports comprises at least one upright truss beam.

Example 11: The system of any of Examples 1 through 10, wherein the support platform comprises at least two support platform segments coupled to each other end-to-end.

Example 12: The system of any of Examples 1 through 11, further comprising a drive mechanism configured to move the robotic arm along the track.

Example 13: The system of any of Examples 1 through 12, further comprising a stop mechanism configured to lock the robotic arm in position along the track.

Example 14: The system of any of Examples 1 through 13, further comprising a lifting mechanism configured to vertically move the support platform along the upright supports.

Example 15: The system of any of Examples 1 through 14, further comprising a bridge movement mechanism configured to horizontally move the bridge platform along the support platform.

Example 16: The system of any of Examples 1 through 15, further comprising at least one position sensor configured to identify a location of the robotic arm relative to at least one of: the bridge platform or the support platform.

Example 17: A method of constructing a building, which may include: positioning upright supports adjacent to a construction site; coupling at least one support platform to the upright supports such that the at least one support platform is vertically movable relative to the upright supports; coupling a bridge platform to the at least one support platform such that the bridge platform is horizontally movable relative to the at least one support platform; mounting a robotic arm to a track supported by the bridge platform such that the robotic arm is movable along the track; and positioning, with the robotic arm, structural insulated panels at the construction site to construct at least a portion of the building.

Example 18: The method of Example 17, further comprising moving the robotic arm along the track to retrieve the structural insulated panels.

Example 19: The method of Example 17 or 18, wherein coupling the at least one support platform to the upright supports comprises coupling at least two support platforms to the upright supports.

Example 20: The method of any of examples 17 through 19, wherein positioning the upright supports adjacent to the construction site comprises: rolling the upright supports with wheels to the location adjacent to the construction site; and deploying outriggers between the upright supports and a ground surface.