Brick laying system

• US 8,965,571 B2
• Filed: 08/10/2011
• Issued: 02/24/2015
• Est. Priority Date: 08/12/2010
• Status: Active Grant

• Current Assignee: Construction Robotics, LLC
• Original Assignee: Construction Robotics, LLC
• Inventors: Peters, Scott Lawrence, Podkaminer, Nathan, Coller, Thomas Charles
• Primary Examiner(s): PATTON, SPENCER D
• Application Number:
  US13/207,328
• Publication Number:
  US 20120053726A1
• Time in Patent Office: 1,294 Days
• Field of Search: 700/245, 700/247, 700/252, 700/258, 901/1, 901/2, 901/9, 901/48, 527/491.4, 414/10, 414/931
• US Class Current: 700/245
• CPC Class Codes: B25J 11/00 Manipulators not otherwise provided for
• CPC Class Codes: B25J 15/0019 End effectors other than grippers
• CPC Class Codes: B66F 11/04 for movable platforms or cabins, e.g. on vehicles, permitting workmen to place themselves in any desired position for carrying out required operations Working platforms on fork-lift trucks B66F9/127; vehicle aspects of service vehicles B60P3/14; platforms for cleaning windows A47L3/02; devices for rescuing persons from buildings A62B1/02; liftable or lowerable platforms for use on ladders E06C7/16; maintenance travellers for bridges E01D19/10; scaffolds on an extensible sub-structure E04G1/22
• CPC Class Codes: E04G 1/04 the members being exclusively poles, rods, beams, or other members of similar form and simple cross-section
• CPC Class Codes: E04G 1/18 adjustable in height lifting devices for movable platforms, e.g. on vehicles B66F11/04
• CPC Class Codes: E04G 21/22 for setting building elements with mortar, e.g. bricklaying machines
• CPC Class Codes: G05B 2219/45086 Brick laying, masonry robot
• CPC Class Codes: Y10S 901/02 Arm motion controller
• CPC Class Codes: Y10S 901/30 End effector
• CPC Class Codes: Y10S 901/41 Tool

Abstract

A brick laying system where an operator such as a mason works proximate a moveable platform having a robotic arm assembly, a mortar applicator with a mortar transfer device, and a brick transfer device to build structures. The robotically assisted brick laying system may also contain a stabilizer having a disturbance sensing and a disturbance correcting component that provides compensation for disturbances caused by load shifting, movement of the platform, wind, operator movement, and the like. In addition, the robotically assisted brick laying system has a sensing and positioning component for controlling placement of the moveable platform and robotic arm assembly. The interoperability of the system with a mason or skilled operator removes much of the manual labor component of brick laying, allowing the mason more time to focus on craftsmanship and quality, thus improving the end product and the overall working conditions of the mason.

Claims

1. A robotically assisted brick laying system, comprising:

a gantry having a moveable platform;

a robotic arm assembly mounted to the moveable platform;

a vibrator mechanically coupled to a brick grasping end effector mounted on the robotic arm assembly;

a master controller having a processor and memory and containing control software;

said master controller operatively coupled to a robot controller;

said robot controller providing instructions to said robotic arm assembly;

a mortar applicator mounted to the moveable platform such that the mortar applicator is stationary with respect to the moveable platform;

a mortar transfer device operatively coupled to said mortar applicator; and

a brick transfer device.

2. A robotically assisted brick laying system in accordance with claim 1, further comprising an end-effector operatively coupled to said robotic arm assembly.

3. A robotically assisted brick laying system in accordance with claim 2, further comprising a locking mechanism mechanically coupled to said end-effector.

4. A robotically assisted brick laying system in accordance with claim 1, wherein in use said mortar applicator moves in reference to a brick placed by the robotic arm assembly.

5. A robotically assisted brick laying system in accordance with claim 1, wherein in use said mortar applicator stationary in reference to the moveable platform and a brick moves across the mortar applicator by the robotic arm assembly to receive mortar.

6. A robotically assisted brick laying system in accordance with claim 1, further comprising a computer aided design (CAD) drawing to stack plan converter.

7. A robotically assisted brick laying system in accordance with claim 1, further comprising a stack plan input to said master controller.

8. A robotically assisted brick laying system in accordance with claim 1, further comprising a laser configured to generate a laser plane and a sensor for receiving said laser plane.

9. A robotically assisted brick laying system in accordance with claim 1, wherein the robotic arm assembly is mounted on a moveable base on the moveable platform.

10. A robotically assisted brick laying system in accordance with claim 1, further comprising site measurement input to said master controller.

11. A robotically assisted brick laying system in accordance with claim 1, wherein the mortar applicator is selected from the group consisting of a progressive cavity pump, a screw pump, a nozzle, a flexible nozzle, a continuous mortar mixer, a mortar pre-form mold, a pre-made mortar package, a conveyor, a vibratory applicator, an adjustable nozzle, and a stationary nozzle.

12. A robotically assisted brick, laying system in accordance with claim 1, wherein the mortar transfer device is selected from the group consisting of a premixed wet mortar transfer device, a dry mortar transfer device, an in line additive mortar transfer device, and a continuous mix mortar transfer device.

13. A robotically assisted brick laying system in accordance with claim 1, wherein the brick transfer device is selected from the group consisting of a transfer station, a cartridge feed system, and a conveyor.

14. A robotic arm assembly for assisting with the task of bricklaying, the robotic arm assembly comprising:

a mounting structure for attaching the robotic arm assembly to a moveable platform;

a brick grasping appendage;

a vibrator mechanically coupled to the brick grasping appendage for improving adhesion of mortar to a brick;

an operator control station;

an electrical coupling coupled to a controller;

a sensor for determining placement position of the brick; and

an interface to a controller for the moveable platform.

15. A method for laying bricks, the method comprising the steps of:

operating a robotic arm assembly attached to a moveable platform;

placing an operator proximate the moveable platform to work with the robotic arm assembly;

providing bricks to the robotic arm assembly;

holding the bricks with an end effector of the robotic arm assembly;

providing mortar to a mortar applicator in proximity to the robotic arm assembly;

moving each brick held by the end effector across the mortar applicator to receive mortar on the brick;

using the robotic arm assembly to place bricks and mortar in a predetermined arrangement;

vibrating the held bricks and mortar with a vibrator attached to the end effector; and

moving the moveable platform as brick laying progresses.