Patent Application
20220356723
This invention relates to a method and apparatus for renovation works on a building, including a method and apparatus for applying a covering to a building element, for example a wall.
Currently, most building renovations are carried out manually on site. A small number of prototype projects have been undertaken where buildings are refurbished using robotic devices. However, building operations on existing buildings, for example installation of external wall insulation, or render, is typically done manually.
Thus, human workers can be required to complete long hours of manual labour to carry out building works, sometimes working in hazardous conditions, such as working at height, or in adverse weather conditions.
Furthermore, it is difficult for human workers to ensure a consistent appearance of a surface of the building before and after rendering the surface, especially if the rendering creates a new surface.
Moreover, when carrying out renovation works a survey is usually conducted to acquire measurements that allow a new part of the building to be built alongside an existing structure, or to allow for a new building to be constructed around the constraints of a given plot of land. For example, for installation of external wall insulation, a frame having insulation panels can be partially constructed to measurements in an offsite location, for example in a factory, and then installed on the building. Render is then manually applied after installation on the building to complete the covering.
It is in this context that the present invention has been devised.
In accordance with the present disclosure there is provided a method for renovation works on a building comprising a plurality of building elements, for example a plurality of walls. The method comprises: receiving scan data of a building element of the building; processing the scan data to determine at least one dimension of the building element and an initial property of the building element from the scan data; configuring a building system for the building element to achieve a target property of the building element, the building system being configured according to the at least one dimension of the building element and according to the initial property of the building element; and generating instruction data for fabricating the building system. Optionally, the method further includes fabricating the building system in accordance with the instruction data. The method is preferably performed by a processor, for example a processor of a computer.
Thus, the building system for the renovation works can be configured according to the at least one dimension and according to the initial property of the building element as captured in the scan data. In this way, the method provides automated configuration of a building system for the renovation works, and outputs instruction data for fabricating the building system. Preferably, the instruction data is in the form of control data for a computer-controlled apparatus that performs at least a part of the fabrication of the building system. That is, preferably the instruction data is control data for a computer-controlled apparatus to automatically fabricate at least a part of the building system based on the control data. Preferably, the computer-controlled apparatus directly fabricates at least a part of the building system based on the control data.
The term “building element” as used herein means any component of a structure of a building. For example, the building element may be a structural element of a building, for example a wall, a roof, a column, a pillar, a beam and any other structural members of the building, such as a chimney stack. In other examples, the building element may be a non-structural element of a building, for example a window, a window sill, a window frame, a fascia, a gutter, a tile, a panel, a fence, a railing, or a balustrade. Therefore, it will be appreciated that the term “building element” may mean any element of a building.
The term “building system” as used herein means a component or a collection of components that go together to make a building element. For example, for a roof, one or more of the rafters, lining, tiles, ceiling boards, insulation and ceiling finish comprise a building system for the roof (building element). In another example, a wall (building element) is comprised of one or more of structural beams/pillars, blockwork, render, panels, insulation, paint and other components, one or more of which comprise a building system. In another example, a window (building element) is comprised of a window frame, a window sill, and one or more window panes, each of which could be a building system.
The term “dimension” means one or more of a height, a width, and/or a depth of the building element. The dimension may be a total height, width or depth of the building element, or may be a partial dimension of the building element.
The term “property” means a non-dimensional property of the building, for example one or more of a thermal metric of the building element, an appearance of the building element, a material of the building element, a condition of the building element, a structure of the building element, and/or a moisture content of the building element.
A thermal metric of the building element may comprise a surface temperature reading, or it may comprise a thermal performance measurement, for example a U-value.
An appearance of the building element may comprise any of a colour, a texture, a shade or other visual characteristic.
A material of the building element will depend on the type of building element. For example, for a wall the material may for example be any of brick, blockwork, concrete, paneling, tiling, etc. For a window frame, the material may for example be any of wood, plastic, metal, etc.
In examples where the initial property and/or the target property include a condition of the building element, the condition may include visible or invisible deficiencies, such as cracks or other weaknesses, or peeling paint, missing parts, leaks, etc, depending on the type of building element. The initial property and/or target property of a condition of the building element may be a binary condition, such as ‘faulty’ or ‘compliant’. For example, a missing gutter might have an initial property of ‘faulty’ and the target property, following replacement of the missing gutter, would be ‘compliant’.
In examples where the initial property and/or the target property include a structure of the building element, the structure may include attachments between different components of the building element, or location information for structural support elements, such as brackets, beams, studs, or joists. The structure may include information on fixing points for attachment of the building system to the building element.
In examples where the initial property and/or target property include moisture, the moisture may include a damp reading, the location of damp areas, identified by moisture content and/or visual characteristics, and/or other indicators of damp.
The method may further comprise determining the target property from the initial property. The target property may be equivalent to the initial property, for example the target property and the initial property may both be a thermal metric of a wall. Specifically, if the initial property were a thermal metric of the building element, then the target property might be a thermal metric of the building element based on the initial thermal metric. However, it will be appreciated that in some examples the method does not include determining, for example computing or calculating, the target property.
The method may comprise classifying the building element, for example through feature recognition based on the scan data. In this example, the initial property may be based on the classification of the building element. Specifically, a particular classification of building element may be associated with one or more initial conditions. In one example, if the building element is classified as a wall, then the initial property may comprise one or more of thermal performance and appearance. Accordingly, the initial property is based on the classification of the building element.
In some examples, the target property matches the initial property. For example, if the initial property were an appearance of the building element, then the target property may match the initial appearance.
In other examples, the target property may be different from the initial property. For example, the target property may be an improvement of the initial property, for example a better thermal metric or an improved condition of the building element.
In some examples, the target property may not be equivalent to the initial property. For example, the initial property may be a structural property, and the target property may be an appearance. In this way, the building system can be configured based on the initial property, so that the building system can be installed on the building, and the building system will achieve a target appearance.
The target property may be retrieved from a database based on the classification of the building element and the initial property. For example, where the building element is a wall and the initial property is a sub-optimal thermal performance, then the target property may be an improved level of thermal performance that is retrieved from a database.
The method may further comprise scanning the building element using electronic scanning apparatus to generate the scan data. The electronic scanning apparatus may comprise one or more directional sensors. The one or more directional sensors may include a camera. The one or more directional sensors may include a rangefinder sensor, such as a laser rangefinder sensor. The one or more directional sensors may include a thermal imaging sensor. The camera may be an optical camera. The camera may be an infrared camera. Thus, the scan data can include spatial information about the building element, for example one or more dimensions, obtained by the rangefinder sensor and/or an optical camera. Additionally or alternatively, the scan data may include thermal information on the building element, for example surface temperatures. Additionally or alternatively, the scan data may include visual information about the building element, as captured by an optical camera. The visual information can be processed to determine an appearance, or a material of the building element.
Preferably, the scan data comprises a 3D point-cloud of the building element. The 3D point cloud is formed of the spatial information from the rangefinder sensor, and may additionally comprise thermal information, visual information, and other scan data layered onto the 3D point cloud.
Preferably, the method further comprises receiving further scan data after fabrication of the building system, and processing the further scan data to assess a resultant property of the building system for quality control. In this way, a subsequent scan can be used to check that the building system has been properly fabricated and installed.
In some examples, fabricating the building system may comprise fabricating a least a part of the building system in a location remote from the building, for example in a factory. The building system can be partially or completely fabricated in the factory, and subsequently installed on the building element. In other examples, fabricating the building system may comprise fabricating the building element at the location of the building, for example directly on the building element. Fabrication of the building system may comprise installing the building system on the building element. Therefore, in some examples the building system can be at least partially fabricated in an off site location, for example in a factory, and later installed onto the building element. In one example, the building system comprises a covering having insulation panels supported by a frame, and a coating applied over the insulation panels, for example a render. In this example, the frame and insulation panels can be fabricated in a factory, installed on the building element (e.g. a wall) and then the render can be applied. Alternatively, the render could be applied at the factory, and the complete covering can subsequently be installed on the building element.
In some examples, configuring the building system may comprise selecting a building system from a database according to the initial property of the building element. For example, a building system may be selected according to its suitability for use with the building element, as determined by the initial property. The building system may be selected according to a classification of the building element. In other examples, configuring the building system may comprise selecting a building system according to the at least one dimension of the building element, in addition to or instead of the initial property of the building element. For example, a replacement component may be specified according to its dimension, such as a length of replacement gutter. In examples where the method includes determining the target property, configuring the building system may comprise selecting a building system from a database according to the target property. In some examples, configuring the building system may comprise selecting a building system from a database according to the initial property, the at least one dimension, and the target property.
The method of configuring the building system may comprise selecting a material and a quantity of the material for the building system according to the at least one dimension of the building element. In this way, the building system can be configured to be the appropriate size and/or shape for the building element. The method of configuring the building system may additionally or alternatively comprise selecting a material and a quantity of the material for the building system according to the initial property of the building element. In examples where the method includes determining the target property, configuring the building system may comprise selecting a material and a quantity of the material for the building system according to the target property. In some examples, configuring the building system may comprise selecting a material and a quantity of the material for the building system according to the initial property, the at least one dimension, and the target property.
The generated instruction data may comprise control data for a computer-controlled apparatus configured to fabricate at least a part of the building system in accordance with the control data. For example, a robotic device or other computer-controlled apparatus may be configured to operate according to the control data to fabricate at least a part of the building system. In one example, an external wall panel can be fabricated by one or more computer-controlled apparatuses in a factory for later installation on a wall of a building. In other examples, the computer-controlled apparatus may comprise computer-controlled apparatus for applying a coating to a building element, for example applying render or plaster. The computer-controlled apparatus may be portable and used on site, at the building, or the computer-controlled apparatus may be in a location remote from the building, for example in a factory. The generated instruction data may comprise control data for more than one computer-controlled apparatus.
Alternatively or additionally, the instruction data may comprise instructions for manual fabrication of at least a part of the building system. For example, the instruction data may comprise drawings, parts lists and assembly drawings for the building system, which can be at least partially manually fabricated.
In some examples, the building system comprises a covering for the building element. For example, the building element may comprise a wall of the building, and the building system may comprise one or more of: a thermal insulation, for example external wall insulation panels, a coating, and/or a decorative feature. In one example, the coating comprises render. A decorative feature may be applied to the render, for example a plurality of brick slips can be applied to the render. In this example, the building system comprises render applied to the wall and brick slips applied to the render before it is fully dry to give an appearance of brickwork. In another example, the building system comprises a coating, such as render, plaster or roughcast, and the coating is shaped after application. The coating may be shaped before fully drying by moving the coating into the desired shape or pattern, or the coating may be shaped after drying by cutting away some of the coating to create the desired shape or pattern. In one example, the desired shape or pattern could comprise lines to mimic blockwork.
In some examples, the building element may comprise an ancillary element of the building. For example, the building element may comprise one or more of: a window, a window sill, a fascia, a gutter, a tile, a panel, a fence, a railing, a balcony, and/or a balustrade. In these examples, the building system may comprise a replacement component for at least a part of the building element, for example a replacement gutter pipe. Alternatively, the building system may comprise a covering for the ancillary element, for example a component that covers a window sill.
In accordance with the present disclosure there is also provided apparatus for performing renovation works, the apparatus comprising: electronic scanning apparatus for scanning a building element to generate scan data; and a processor configured to:
In some examples, the apparatus may further comprise computer-controlled apparatus for fabricating the building system in accordance with the instruction data. For example, the apparatus may comprise a computer-controlled apparatus for applying a coating, as described below. In other examples, the apparatus may comprise a computer-controlled cutting machine to cut parts for fabrication of the building system. In some examples, the computer-controlled apparatus may be in a location remote from the building, for example in a factory, to fabricate at least a part of the building system for subsequent installation on the building element. In other examples, the computer-controlled apparatus is portable, and can be used to fabricate at least a part of the building system at the location of the building, for example directly on the building element. Preferably, the electronic scanning apparatus is separate to the computer-controlled apparatus for fabricating the building system. The apparatus may further comprise a control device, and the control device may comprise the processor.
In accordance with the present invention, there is also provided a method for building works, the method comprising:
In this way, a new building element can be configured according to the scan data of the existing building, for example to have an appropriate size and/or to match an appearance of the existing building. In one example, the new building element may be a new wall, for example a wall of an extension, and the size and position of windows in that new wall can be configured to match the size and position of windows in the existing building.
In some examples, the new building element is an extension for the existing building, the extension being configured for connection to the existing building element. For example, the new building element may be a porch configured based on the scan data of a wall of the existing building, including dimensions of the wall, and positions of windows and doors, as well as an appearance of the wall, for example brick colour and arrangement. Advantageously, the porch could be fabricated in an off-site location, for example in a factory, based on the generated instruction data. The fabricated porch can then be installed on the existing building. In another example, the extension for the existing building may be a new terraced house to be built on the end of an existing terraced house. The new terraced house may be configured to match the dimension and appearance of the existing terraced house by configuring the new terraced house based on the scan data of the existing terraced house, in particular the dimension and initial property of the existing terraced house.
In other examples, the new building element may be a separate building to the existing building, for example a garage or outbuilding. In this example, the new building element is not connected to the existing building, but is configured according to the scan data of the existing building, in particular the dimension and the initial property. In one example, the new building element may be a new building, for example a new house. In this example, the separate building may be at least a partial replica of the existing building. For example, scan data of an existing building may be used to configure a new building to have the same size and appearance of the existing building. The new building can then be fabricated, according to the generated instructed data, for construction at any location.
In accordance with the present disclosure there is also provided a method of applying a covering to a building element of a building, for example a wall. The method comprises: receiving scan data of a building element of the building; processing the scan data to determine an initial property of the building element from the scan data; configuring a covering for the building element, the covering comprising a coating configured to achieve a target property of the building element; generating control data to control a computer-controlled apparatus for applying the coating of the covering; and controlling the computer-controlled apparatus for applying the coating in accordance with the control data.
Thus, the covering for the building element, in particular the coating, can be provided by computer-controlled apparatus to achieve the target property based on a scan data of the building element. Therefore, manual labour is reduced or even eliminated, and supervision of application of the coating to achieve the target property of the building element can be reduced or even eliminated, increasing safety for human workers. The building element may be part of an existing building, and the method may be a method of retrofitting the covering to the building element.
In some embodiments, the scan data may be obtained previously, or by a separate method, and therefore in the method according to the present disclosure the scan data is received. Alternatively, the method may further comprise scanning the building element using electronic scanning apparatus to generate the scan data. The electronic scanning apparatus may comprise one or more directional sensors. The one or more directional sensors may include a camera. The one or more directional sensors may include a rangefinder sensor, such as a laser rangefinder sensor. The one or more directional sensors may include a thermal imaging sensor. The camera may be an optical camera. The camera may be an infrared camera. Thus, the scan data can include spatial information about the building element, for example one or more dimensions, obtained by the rangefinder sensor and/or an optical camera. Additionally or alternatively, the scan data may include thermal information on the building element, for example surface temperatures. Additionally or alternatively, the scan data may include visual information about the building element, as captured by an optical camera. The visual information can be processed to determine an appearance, or a material of the building element.
In some examples, the coating is applied to the building element. For example, the building element may comprise a wall and the coating may comprise a render, and the render may be applied to the wall.
In other examples, the covering further comprises insulation for attachment to the building element, and the coating may be applied to the insulation. For example, the insulation may comprise one or more insulation panels. The insulation panels may be attachable directly to the building element, or the insulation may further comprise a frame arranged to support the one or more insulation panels. The coating can be applied to the insulation after attachment of the insulation to the building element, or before attachment of the insulation to the building element. For example, the method may comprise fabrication of at least a part of the covering in a location remote from the building, for example in a factory. In a specific example, the insulation (insulation panels and optional frame) can be fabricated in a factory for subsequent installation on the building element. The coating, for example a render, may be applied at the location remote from the building, for example at the factory, or the coating may be applied after attachment of the insulation to the building element. The method may further comprise installing the covering on the building element. In preferred examples, the coating comprises render or plaster or roughcast.
In some preferred examples, the building element is a wall of the building. In other examples, the building element may be a roof or a floor, and the coating may comprise different materials, for example bitumen, or a spray on polymer coating. The coating may alternatively or additionally comprise paint.
In some examples, configuring the covering comprises selecting a covering from a database according to the initial property of the building element. For example, the initial property may comprise structural information, and the covering can be selected to be compatible with the structural information. The covering may also be configured based on a classification of the building element. In another example, the initial property may comprise an initial appearance, and the covering can be selected according to the initial appearance, for example to match the initial appearance. Alternatively or additionally, configuring the covering may comprise selecting a covering from a database according to the target property of the building element. For example, the target property may be an appearance or a thermal metric, and the covering can be selected to achieve that appearance or thermal metric. The method may further comprise determining the target property from the initial property.
Configuring the covering may additionally or alternatively comprise selecting at least one of a material and a quantity of the material to be used to achieve the target property of the building element based on the scan data. For example, a quantity of material for the coating may be based on one or more dimensions of the building element, or the type of material may be based on an initial structural property of the building element.
The method may further include processing the scan data to determine at least one dimension of the building element. In this example, configuring the covering may comprise configuring the covering according to the dimension, optionally in combination with the initial property and/or the target property.
The method may include determining the target property, for example computing or calculating the target property based on the initial property. Alternatively, the target property may be determined by user input. However, in some examples the target property is not determined. The target property may be assumed. For example, installing insulation to a wall may be assumed to improve a thermal metric of the wall.
The initial property of the building element may include an appearance of the building element. The initial property of the building element may include a thermal metric of the building element. Thus, the covering for the building element can be generated based on the appearance of the building element and/or based on the thermal metric of the building element. Similarly, the computer-controlled apparatus for applying a coating can be controlled to apply a coating to achieve a target property of the building element, which can be the appearance of the building element and/or the thermal metric of the building element, based on the control data.
The appearance may include a shape of the surface of the building element. The appearance may include a colour of the surface of the building element. The appearance may include a texture of the surface of the building element.
It will be appreciated that the scan data may be indicative of a plurality of initial properties of the building element, for example appearance, material, and condition. Similarly, it will be appreciated that the covering may be configured to achieve a plurality of target properties of the building element.
The target property may be configured to match the initial property. The target property of the building element can be substantially the same as, for example exactly the same as, the initial property of the building element. For example, the control data can be to control the computer-controlled apparatus to apply a coating to achieve the same appearance of the building element following application of the covering as the appearance of the building element prior to application of the covering, even if another target property of the building element may be different to another initial property of the building element as a result of applying the covering. For example, a first target property may be the appearance, which can match the initial appearance of the building element, and a second target property may be a thermal metric, which can differ from the initial thermal metric, for example it may be an improved thermal metric.
As will be appreciated from the above, in some examples the target property differs from the initial property. For example, the target property may be an improvement of the initial property.
In some examples, the method further comprises shaping the coating after application of the coating. For example, the coating may be shaped before the coating material has dried. For example, if the coating comprises render, the render can be smoothed or otherwise shaped before the render has dried. In other examples, the coating may be cut after drying in order to shape the render. For example, a router may be used to cut the coating after drying. In one example, the coating is provided with lines that mimic blockwork.
In a further example, the method may further comprise applying a decorative feature to the coating, for example one or more brick slips. The brick slips can be applied to the coating before the coating has dried, to secure the brick slips to the coating.
In preferred examples, the computer-controlled apparatus comprises a material output nozzle and an actuator for moving the material output nozzle, the actuator and the material output nozzle being operable in accordance with the control data. In some examples, the method further comprises performing a location registration operation to determine a location of the computer-controlled apparatus for applying the coating based on the scan data. In this way, the computer-controlled apparatus can determine its position relative to the building element in order to apply the coating.
The method may further comprise scanning the building element after application of the covering to capture further scan data indicative of the target property of the building element. In other words, the further scan data can be generated based on a further scan of the building element subsequent to application of the covering. The method may further comprise determining a quality control characteristic of the covering based on the further scan data. Thus, the performance of the computer-controlled apparatus for applying a coating, and/or the quality of the coating, can be assessed. The quality control characteristic may be additionally based on the scan data indicative of the initial property of the building element.
Viewed from another aspect, the present disclosure provides apparatus for applying a covering to a building element of a building, for example a wall. The apparatus comprises: electronic scanning apparatus configured to scan the building element to generate scan data indicative of an initial property of the building element; and a computer-controlled apparatus for applying a coating of the covering. The apparatus further comprises a processor configured to: receive scan data from the electronic scanning apparatus; process the scan data to determine an initial property of the building element from the scan data; configure a covering for the building element, the covering comprising a coating configured to achieve a target property of the building element; generate control data to control a computer-controlled apparatus for applying the coating of the covering; and control the computer-controlled apparatus for applying the coating in accordance with the control data.
In examples, the electronic scanning apparatus may be separate from the computer-controlled apparatus for applying the coating. The apparatus may further comprise a control device, the control device being separate to the electronic scanning apparatus. The control device may comprise the processor.
The computer-controlled apparatus for applying the coating may comprise a material output nozzle for outputting a coating material, and an actuator to control a position of the material output nozzle.
The computer-controlled apparatus for applying the coating may additionally or alternatively comprise a smoothing tool for smoothing the coating material after application by the material output nozzle. Alternatively or additionally, the computer-controlled apparatus for applying the coating may comprise a shaping tool for shaping the coating.
The computer-controlled apparatus for applying the coating may be configured to apply a coating material, for example render or plaster or roughcast. The coating material can be applied in fluid form, such as in a slurry of mixed sand, cement and water. The coating material can subsequently be moved, smoothed, or shaped before being allowed to dry and set.
After the coating material has dried and set, the coating may be shaped by cutting the coating to remove material. For example, using a router to cut away some of the coating to shape the coating.
As described above, in examples, the covering may be configured according to the initial property of the building element and/or according to the target property of the building element. The target property may comprise an appearance of the building element.
The computer-controlled applicator may comprise a tool and a support structure arranged to support the tool. The support structure may comprise an actuator for operation in accordance with the control data. The control data may be to control the computer-controlled apparatus to apply a coating to achieve the target property of the building element utilising the tool. The actuator may be configured to move the tool through a plurality of positions to apply the coating. It will be understood that the tool may be substantially any tool, for example a material output nozzle, a smoothing tool, or a shaping tool.
In some examples the support structure comprises an articulated arm, and wherein the actuator is configured to be operated in accordance with the control data to move the articulated arm.
In other examples, the support member may comprise: a first member; a second member spaced from and substantially parallel to the first member; and a cross-member connecting the first member to the second member and mounted to both of the first member and the second member for movement in a direction parallel to the first member and the second member. A first actuator may be arranged to move the cross-member in a direction parallel to the first member and the second member. Additionally, the tool may be mounted to the cross-member for movement relative thereto in a longitudinal direction of the cross-member between the first member and the second member. A second actuator may be provided to move the tool in the longitudinal direction of the cross-member. Thus, the support member may be in the form of a gantry.
The apparatus may be configured to move the tool in a direction transverse to the longitudinal direction and the direction parallel to the first member and the second member. Thus, where the first member, the second member and the cross-member are provided substantially parallel to the building element, the tool can be moved towards or away from the building element to apply a covering to the building element to achieve the target property of the building element. In an embodiment, the tool may be configured to move towards or away from the building element by movement relative to the cross-member. In another embodiment, the tool may be configured to move towards or away from the building element by movement of the tool in combination with the cross-member, and optionally also in combination with the first member and the second member. In other words, the whole support member may be configured to move towards or away from the building element.
In a preferred embodiment the apparatus is portable, preferably the computer-controlled apparatus is portable. The computer-controlled apparatus may be configured to apply a coating to a structure for attachment to the building element, the structure and coating together forming the covering. The computer-controlled apparatus may be configured to apply the coating to the structure after attachment of the structure to the building element. Alternatively, the computer-controlled apparatus may be configured to apply the coating to the structure before attachment of the structure to the building element. Thus, the apparatus, in particular the computer-controlled apparatus, may apply the coating to the structure off site, for example in a factory, for later attachment to the building element. The structure may comprise one or more insulation panels and optionally a frame.
It will be understood that the term portable should be taken to mean that the portable apparatus can be provided temporarily in location at the building. Therefore, the portable apparatus can be removed from the building after use.
It will be understood that any data processing, for example processing the scan data to generate the control data or instruction data, can be performed by a device having one or more processors and a memory including instructions to cause the one or more processors to perform the data processing, such as to process the scan data to generate the control data or instruction data. The memory is typically a non-transient computer-readable storage medium.
In the various examples described above, scanning the building element may comprise scanning the building element with a rangefinder sensor, for example a laser rangefinder sensor. The scan data from the rangefinder sensor may comprise a 3D point cloud of the building element. In addition, scanning the building element may comprise capturing images of the building element using an optical camera, in particular still images. Scanning the building element may additionally or alternatively comprise capturing thermal information on the building element using a thermal sensor. The 3D point cloud may be combined with the images and/or the thermal information to form a multi-layered 3D point cloud of the building element. Such a multi-layered 3D point cloud comprises spatial information (from the rangefinder sensor), visual information (from the optical camera) and thermal information (from the thermal sensor). The multi-layered 3D point cloud can be processed to determine the at least one dimension of the building element and the initial property of the building element.
Processing the scan data, in particular the 3D point cloud, to determine the at least one dimension and the initial property may comprise feature recognition based on the spatial information (from the rangefinder sensor), and/or the visual information (from the optical camera), and/or thermal information (from the thermal sensor). Feature recognition may comprise image recognition to classify the building element (e.g. wall, window, roof). Feature recognition may additionally comprise classifying the initial property (e.g. thermal performance of a wall, or appearance of a window). The initial property may be identified by comparing the scan data to a database of building elements with corresponding classification. For example, the material of a wall can be determined by comparing images of the scanned wall to images of other walls stored in a database to determine the material and/or appearance of the scanned wall.
Feature recognition may additionally comprise identifying the position or location of a border of the feature. For example, feature recognition may comprise identifying the position of a window frame or a door frame.
Configuring the building system to achieve the target property may comprise retrieving a target property from a database according to the classification of the building element and the initial property. For example, if a scanned wall has a sub-optimal initial thermal performance then configuring the building system may comprise selecting, from a database, a building system that improves the thermal performance of the wall, for example selecting an external wall insulation building system. The building system is further configured according to the at least one dimension of the building element such that the selected building system is configured for the building element, i.e. sized to fit. For example, the building system may be configured to abut a feature, such as a window frame or a door frame.
The step of generating instruction data for fabricating the building system may comprise processing the scan data, in particular the 3D point cloud, and the configured building system together to generate instruction data.
In preferred examples, the instruction data comprises control data for a computer-controlled apparatus configured to fabricate the building system. The control data may comprise a route or path for movement of a tool of the computer-controlled apparatus. The route can be configured within the 3D point cloud so that the route is spatially matched to the building element. The route may take account of the position of a building element, for example the position of a window frame or a door frame within a wall.
In one example, the computer-controlled apparatus comprises a multi-axis robotic apparatus having a tool that can be moved through a plurality of axes of movement, for example two axes, 3 axes, 4 axes, or 5 axes of movement. An actuator is arranged to move the tool about each of the axes of movement. The route that is configured for fabricating the building system may comprise control data for each actuator over a time period for fabricating the building system, so that during fabrication of the building system the tool is moved according to the control data to fabricate the building system.
In one example, where the building element comprises a wall and the building system comprises a sprayed insulation material, the computer-controlled apparatus comprises an insulation spray nozzle that can be moved through multiple axes of movement in order to move the insulation spray nozzle over the wall to spray insulation material onto the wall and form a covering. Each axis of movement is provided by an actuator. In this example, the control data for the computer-controlled spray apparatus may comprise a spray path comprising control data for controlling the actuators to move the insulation spray nozzle, and spray control data for controlling spraying of the insulation material. Such control data for the computer-controlled spray apparatus can be generated based on the scan data, in particular the 3D point cloud.
Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which:
In examples, the electronic scanning apparatus may comprise the sensor apparatus described in the Applicant's co-pending patent application WO2020/079394. Additionally or alternatively, the electronic scanning apparatus may comprise the sensors, processors, and other features as described in any of the Applicant's earlier patent applications, in particular WO2017/220716, WO2016/207627, and/or WO2014188221.
It will be understood that the appearance of a building element means any visual aspect of the building element, including but not limited to the shape, colour and/or texture of the building element. In an example, the computer-controlled apparatus is controlled to carry out an operation to apply a coating to the building element to achieve a target property of the building element to match the initial property of the building element. For example, the computer-controlled apparatus may be controlled to apply a coating to the building element such that the appearance of the building element after application of the coating has substantially the same colour as the appearance of the building element prior to application of the coating. In other words, a person may be unable to see a difference in the colour of the building element when the building element surface had the initial property and when the coating has been applied to achieve the target property of the building element. In another example, the computer-controlled apparatus may be controlled to apply a coating to the building element to achieve the target property of the building element such that the texture of the building element achieved by applying the coating is substantially the same as the texture of the building element prior to applying the coating. In other words, a person may be unable to see a difference in the texture of the building element when the building element had the initial property and when the coating has been applied to the building element to achieve the target property. In yet another example, the computer-controlled apparatus may be controlled to apply a coating to the building element to achieve the target property of the building element such that the 3D shape of the building element achieved by application of the coating is substantially the same as the 3D shape of the building element prior to application of the coating. In other words, a person may be unable to see a difference in the 3D shape of the building element when the building element had the initial property and when the coating has been applied to the building element to achieve the target property. In this way, it can appear that the appearance of the building element achieved by applying the coating aesthetically matches the appearance of the building element prior to application of the coating, in one or more ways. Where the building element is formed to have a certain appearance prior to application of the coating using the computer-controlled apparatus, such as a brickwork appearance (for example because the surface of the building element is formed from brick), the target property of the building element may be configured such that the building element also has a brickwork appearance after application of the coating, based on the received scan data, indicative of the brickwork appearance of the building element prior to application of the coating.
Applying a covering to the building element by the computer-controlled apparatus to achieve the target property of the building element in the third step 130 can include performing any one or more operations to achieve the target property of the building element, as will be discussed further with reference to
The method 100 can comprise determining, for example selecting, a material to be used in the operation to be carried out by the computer-controlled apparatus based on the scan data received in the second step 120. For example, the material can be selected so as to be usable by the computer-controlled apparatus to achieve a desired new appearance of the building element which is determined based on the appearance of the building element prior to application of the covering using the computer-controlled apparatus. The method 100 can additionally or alternatively comprise determining, for example selecting, an amount of material to be used in the operation based on the scan data received in the second step 120. In this way, by determining precisely the amount of material which will be required, wastage can be reduced, as well as the overhead in time, energy and cost in transporting unnecessary material.
The method 100 can comprise additional scanning operations after the covering has been applied to achieve the target property of the building element, for example for quality control purposes. In an example, the method 100 comprises scanning the building element subsequent to the application of the covering to generate further scan data. One or more quality control characteristic, such as a thermal conductivity, a visual appearance or a depth may be determined based on the further scan data. In some examples, a difference characteristic between the resultant property of the building element and the initial property of the building element may be determined based on the further scan data and the previous scan data generated in the first step 110.
In some examples, further scans may be performed as part of applying the covering to the building element to achieve the target property. For example, a higher fidelity scan can be performed at or immediately before the time at which the covering is applied to achieve the target property of the building element to allow a more precise model of the initial property of the building element to be determined.
In further examples, the method 100 can comprise performing a location registration operation. The location registration operation can be performed after the scan of the building element by the electronic scanning apparatus and prior to or as part of application of the coating by the computer-controlled apparatus. The location registration operation will locate the computer-controlled apparatus relative to the building element. Typically, the location registration operation comprises performing a location registration scan of the building element to generate location registration data. The location registration scan is indicative of the location of the computer-controlled apparatus, for example because the location registration scan is performed by the computer-controlled apparatus. The location of the computer-controlled apparatus relative to the building element can be determined based on the location registration data. Typically, the location of the computer-controlled apparatus is determined based on a comparison of the location registration data and the scan data. In this way, the location of the computer-controlled apparatus relative to the building element can be accurately determined. In some examples, markers can be provided one feature of the building which will remain unchanged by application of the covering to the building element, for example, stickers can be placed on the windows of the building. The stickers may provide a location registration target which can be detected in the scan of the building element to generate the scan data and in the location registration scan of the building element to generate the location registration data. In this way, the location of the computer-controlled apparatus can be determined relative to the original building element, based on the detected location of the location registration target in the location registration data, even if the covering has been, or has begun to be, applied to the building element to achieve the target property of the building element.
The method may further comprise performing a location registration operation using the computer-controlled apparatus to determine a location of the computer-controlled apparatus relative to the building element of the building based on the scan data. Thus, the location of the computer-controlled apparatus can be determined based on the previous scan data indicative of the initial property of the building element. The location of the computer-controlled apparatus can be additionally determined based on location data of the computer-controlled apparatus. The location data may be determined based on registration scan data of the computer-controlled apparatus. The registration scan data may be generated based on a registration scan of the building element by the computer-controlled apparatus. The registration scan may be performed prior to application of the covering to the building element to achieve the target property of the building element. The registration scan data may be aligned with the scan data to determine the location of the computer-controlled apparatus relative to the building element. Thus, accurate location information for the computer-controlled apparatus can be determined.
In the example method of
Also shown in
Thus, in this example, the electronic scanning apparatus 10 is configured to scan a wall of the building 200. However, it will be understood that in other examples, the electronic scanning apparatus 10 can be configured to scan another building element of the building 200, such as windows or doors, as explained hereinafter with reference to
The electronic scanning apparatus 10 typically comprises one or more directional sensors, for example a plurality of directional sensors, including at least an optical camera and a rangefinder sensor in order to generate a model of a building element to define an original appearance of the building element. In examples, the electronic scanning apparatus 10 can also comprise a thermal sensor. The scan data generated by the electronic scanning apparatus 10 may comprise a 3D point cloud generated using spatial information from the rangefinder sensor. Other scan data, or example optical images and thermal information, may be layered onto the 3D point cloud to provide a multi-layered 3D point cloud model of the building element.
The electronic scanning apparatus 10 can be moveable, for example on wheels or tracks, or as an airborne vehicle, such as a drone. In some examples, the electronic scanning apparatus 10 can be moved between positions by a human operator.
Although the scanning beam 20 is shown as a flat, substantially horizontal scanning beam, it will be understood that other shapes of beam may be provided. The scanning beam may be in a direction other than substantially horizontal, for example substantially vertical. In some examples, the scanning beam can be a region rather than a line, for example a rectangular region or a substantially circular region. In other words, the electronic scanning apparatus 10 can be configured to scan in a region including one or more building elements of the building 200. The scanning apparatus 10 may be moved in a scanning motion, for example by moving the scanning apparatus 10 in a linear or rotational manner, to move the scanning beam 20 across the surface being scanned.
As can be seen, the wall 205a in
It will be understood that any of the electronic scanning apparatus disclosed herein may additionally or instead be used to scan a building element of the building whilst a covering is being applied to the building element, or during other construction or renovation work, to achieve a target property of the building element. Alternatively, the electronic scanning apparatus can be used to scan the building element subsequent to the building element having a covering applied to it, or after other construction or renovation works, to achieve a target property of the building element.
It will be understood that each of the electronic scanning apparatus disclosed herein will typically generate scan data indicative of an initial property of the building element as a result of scanning the building element. In some examples, the electronic scanning apparatus may also process the scan data to generate control data. The control data may be to control a computer-controller apparatus, for example a robotic device, to apply a covering to the building element to achieve a target property of the building element, as per the method illustrated in
In this example, the robotic device 660 is configured to apply a coating to the wall 205a by carrying out a render application operation on the wall surface 210a. The tool head 680 progresses over the wall surface 210a, outputting render material 687 onto the wall surface 210a to apply a coating to the wall 205a to form a covering to achieve a target property. In this way, a new surface is provided to replace the wall surface 210a, by covering the wall surface 210a. In this example, the tool head 680 progresses upwards over the wall surface 210a. It will be understood that, in some examples, further operations may be required to achieve the target property of the wall 205a.
The robotic device 660 is controlled in accordance with control data. Typically, the control data is generated by processing the scan data described hereinbefore, indicative of an initial property of the building element, in this example the wall 205a. The control data is to control the robotic device 660 to apply a coating to the wall 205a to achieve the target property of the wall 205a. Thus, it can be seen that the control data is determined in dependence on the scan data. In some examples, the target property of the wall 205a can be determined in dependence on the initial property of the wall 205a indicated by the scan data. It will be understood that the control data can be received by the robotic device from a further device, such as the electronic scanning apparatus, in data communication with the robotic device. Alternatively, the control data can be generated by the robotic device based on the scan data, which is received by the robotic device from the further device, for example the electronic scanning apparatus, in data communication therewith.
In some examples, the robotic device 760 of
It will be understood that although the examples of
In this example, the underlying coating may be applied by the apparatus of any of
In an alternative example the individual brick slips 222 can be individually applied to render coating to secure them to the wall 205a, without use a mesh to hold them together.
In alternative examples the brick slips 222 of the brick slip covering 220 shown in
The insulation panels 231 form a covering that may be applied to the wall 205a to achieve a target property of the wall 205a, for example improved thermal efficiency.
In some examples, the insulation panels 231 are applied or attached directly to the wall 205a, without the frame 232 illustrated in
After application of the insulation panels 231 to the wall 205a the insulation panels 231 and optional frame 232 can be provided with a coating, for example a render coating, as illustrated in
In alternative examples, the insulation panels 231 can be provided with an outer cover in the form of cover panels, for example metal or ceramic panels, that cover and protect the insulation. The cover panels can be applied to form an outer cover that achieves a target property of the building element 205a, for example an appearance or weather-proofing.
In some examples, fabrication of the covering 230, including the frame 232 and insulation panels 231, can be performed off site, that is, in a location remote from the building element 205a. The fabrication can be performed in a factory. In one example, a computer-controlled apparatus in a factory at least partly fabricates the frame 232 and the insulation panels 231 to form a covering 230 that can then be transported to the building element 205a for attachment to form a covering 230 on the building element 205a. Specifically, computer-controlled apparatus in a factory may cut frame members and insulation panels according to control data, and these frame members and insulation panels can be assembled to form the covering 230. A computer-controlled apparatus may also perform assembly tasks to assemble the frame members and insulation panels 231.
In some examples, a coating is applied to the covering 230, for example a render coating. The coating can be applied to the insulation panels 231 and frame 232 at the off site location, i.e. at the factory. The render can be applied by a computer-controlled apparatus operated in accordance with the control data, for example any of the robotic apparatus 660, 760, 860, 960 illustrated in
In the example of
In the example of
It will appreciated that the apparatus 1400 described with reference to
In an alternative example, a combination of off site and on site fabrication is employed, for example by fabricating the frame 232 and insulation panels 231 in a factory, attaching the frame 232 and insulation panels 231 to the building element 205a, and then applying a coating, for example render coating, on site to complete the covering 230 for the building element 205a.
The examples of
The method 180 will comprise the second step 150 and the third step 160 even when the scan data has not been generated as part of the first step 140 of the method 180. For example, the scan data may be received from a data storage and the scan data may have been generated not as part of the method. In this case, the method can comprise receiving the scan data, such as from the data storage.
In this way, a building system for the building element, for example a covering or a replacement component, can be configured according to the determined dimension and according to the initial property of the building element, indicated by the scan data.
In some preferred examples of the method 180, the building element is a wall of the building, and the wall comprises a surface. In this case, the building system may comprise a coating, for example a render, for application to the wall to form a covering, similarly to the examples described with reference to
In other examples of the method 180, the building element is an ancillary component of the building, for example a window, a window frame, a window sill, a fascia, a gutter, a tile, a panel, a fence, a railing, or a balustrade. In these examples, the building system may be a covering, or it may alternatively be a replacement component for at least a part of the ancillary element.
The step 150 of determining at least one dimension of the building element comprises determining from the scan data one or more of a height, a width, and/or a depth of the building element or a part of the building element. The step 150 of determining an initial property of the building element comprises determining from the scan data a non-dimensional property of the building element, for example a thermal metric of the building element, an appearance of the building element, a material of the building element, a condition of the building element, a structure of the building element, or a moisture content of the building element. The step 150 of determining a non-dimensional property of the building element may comprise comparing the scan data, or a part of the scan data, to a database in order to classify and recognise the non-dimensional property, for example appearance.
According to the determined dimension and initial property of the building element, the method step 160 configures a building system for the building element to achieve a target property. For example, as mentioned above, the building system may be a covering, or it may be a replacement component, and the building system will be configured for the specific building element that was scanned.
The target property may be an improvement of the initial property, for example an improved thermal metric, or the target property may be configured to match the initial property, for example a matching appearance. Therefore, the target property may be the same as, or different from, the initial property.
In method step 160, configuring the building system may include selecting a building system from a database according to the dimension, the initial property and/or the target property of the building element. For example, if the initial property indicated a faulty or missing gutter, the method step 160 of configuring the building system may comprise selecting a replacement gutter component from a database based on the length of gutter component needed (dimension) and the colour (initial property).
Additionally or alternatively, the method step 160 of configuring the building system may comprise selecting a material and a quantity of the material for the building system. For example, if the building system were a render coating, as described above, selecting an amount of render required according to the determined dimension and determined initial property of the building element.
The instruction data generated in method step 170 preferably comprises control data for a computer-controller apparatus to fabricate at least a part of the building system. For example, the control data may be for the computer-controlled apparatus described elsewhere herein with reference to
Alternatively or additionally, the method step 170 of generating instruction data may include generating instructions to be manually performed. For example, instructions for manual fabrication and/or installation for at least a part of the building system. The instruction data may comprise control data for a computer-controlled apparatus and instructions for manual fabrication tasks. For example, the instruction data may comprise control data for a CNC cutting machine to fabricate parts of a frame, and manual instructions for assembly of the parts of the frame into a frame.
The method 180 may comprise the further step of fabricating the building system in accordance with the instruction data generated in method step 170.
The step of fabricating the building system may comprise manufacturing and/or assembling the building system, and may further comprise installing the building system. As described with reference to
The method 180 can comprise additional scanning operations after the building system has been fabricated and/or installed, for example for quality control purposes. One or more quality control characteristics, such as a thermal metric, a visual appearance or a depth may be determined based on the further scan data. In some examples, a difference characteristic between the resultant property of the building element and the initial property of the building element may be determined based on the further scan data and the previous scan data generated in the first step 140.
As per the method of
As per the method of
As per the method of
As per step 170 of the method of
According to the method 171 of
In this way, a new building element can be configured according to the scan data of the existing building 200, for example to have an appropriate size and/or to match an appearance of the existing building 200. In one example, the new building element may be a new wall, for example a wall of an extension, and the size and position of windows in that new wall can be configured to match the size and position of windows 206 in the existing building 200.
In some examples, the new building element is an extension for the existing building 200, the extension being configured for connection to the existing building element, for example a wall 205a of the building 200 in
Advantageously, the porch or other extension could be fabricated in an off-site location, for example in a factory, based on the generated instruction data. The fabricated porch can then be installed on the existing building 200.
In another example, the extension for the existing building 200 may be a new terraced house to be built on the end of an existing terraced house. The new terraced house may be configured to match the dimension and appearance of the existing terraced house by configuring the new terraced house based on the scan data of the existing terraced house, in particular the dimension and initial property of the existing terraced house, for example an appearance of the existing terraced house.
In other examples, the new building element may be a separate building to the existing building 200, for example a garage or an outbuilding. In this example, the new building element is not configured for connection to the existing building 200, but is configured according to the scan data of the existing building 200, in particular the dimension and the initial property determined from the scan data. In one example, the new building element may be a new building, for example a new house. In this example, the separate building may be at least a partial replica of the existing building 200. For example, scan data of an existing building 200 such as shown in
The method 171 may further comprise a step of generating the scan data of the existing building, for example by using the scanning apparatus 10,210,310, 410 of
The step 173 of determining at least one dimension of the existing building element comprises determining from the scan data one or more of a height, a width, and/or a depth of the existing building element or a part of the existing building element. The step 173 of determining an initial property of the existing building element comprises determining from the scan data a non-dimensional property of the existing building element, for example an appearance of the existing building element, a material of the existing building element, a condition of the existing building element, or a structure of the existing building element.
According to the determined dimension and initial property of the building element, the method step 174 configures at least one new building system for the new building element to achieve a target property. For example, as mentioned above, the new building element may be an extension, for example a porch, or the new building element may be a replica house, and the one or more new building systems will be configured based on the existing building element that was scanned.
The target property may be an improvement of the initial property, for example an improved thermal metric, or the target property may be configured to match the initial property, for example a matching appearance. Therefore, the target property may be the same as, or different from, the initial property.
In method step 174, configuring the one or more new building systems may include selecting one or more new building systems from a database according to the dimension and/or the initial property of the existing building element. For example, if the initial property indicated a particular brick colour and arrangement, then the method step 174 of configuring the one or more new building systems may comprise selecting a brick for use in the new building element.
The instruction data generated in method step 175 preferably comprises control data for a computer-controller apparatus to fabricate at least a part of the one or more new building systems, and may include control data for a computer-controlled apparatus to fabricate a plurality of new building systems to provide a new building element. For example, the control data may be for the computer-controlled apparatus described elsewhere herein with reference to
Alternatively or additionally, the method step 175 of generating instruction data may include generating instructions to be manually performed. For example, instructions for manual fabrication and/or installation for at least a part of one or more of the new building systems. The instruction data may comprise control data for a computer-controlled apparatus and instructions for manual fabrication tasks. For example, the instruction data may comprise control data for a CNC cutting machine to fabricate parts of a frame, and manual instructions for assembly of the parts of the frame into a frame.
The method 171 may comprise the further step of fabricating the one or more new building systems in accordance with the instruction data generated in method step 174.
The step of fabricating the one or more new building systems may comprise manufacturing and/or assembling the one or more new building systems, and may further comprise installing the one or more new building systems and/or the new building element. As described with reference to
The method 171 can comprise additional scanning operations after the new building system has been fabricated and/or installed, for example for quality control purposes. One or more quality control characteristics, such as a thermal metric, a visual appearance or a depth may be determined based on the further scan data. In some examples, a difference characteristic between the resultant property of the new building element and the initial property of the existing building element may be determined based on the further scan data and the previous scan data generated in the first step 172 of the method 171.
Either or both of the electronic scanning apparatus and the computer-controlled apparatus can be controlled by a control unit, for example comprising one or more processors and a non-transient computer readable storage medium, sometimes referred to as a memory. The memory can include instructions which, when executed, cause the one or more processors to control either or both of the electronic scanning apparatus and the robotic device to operate as described herein. The control unit may be part of either or both of the electronic scanning apparatus and the robotic device, or may be separate to the electronic scanning apparatus and the robotic device.
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Features, integers, characteristics or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1909111.5 | Jun 2019 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2020/051535 | 6/24/2020 | WO |
