Patent Application
20130310971
This invention relates generally to methods and apparatus for transferring plan information to construction sites and relates particularly to apparatus and methods for establishing reference positions upon the floor portions of construction sites.
In most building construction, a detailed plan is initially created which provides a series of drawings setting forth the dimensions and character of the building to be constructed. Additional information is found in such drawings or plans which establishes other critical information such as location of exterior and interior walls, location of facilities such as plumbing and ventilation and other structural information such as the locations of doors, windows and stairways. Historically, such building plans were known generally as “blue prints” deriving their name from the blue on white printing systems used in their creation.
While the construction methods utilized in various buildings is subject to substantial variation, typically one or more concrete floors are poured and formed as a building base. Often the concrete floors house various elements such as plumbing pipework, conduits, and drains many of which travel beneath or through the poured concrete floor. In most building construction, the first floor concrete is allowed to cure to a sufficient extent to provide strength and stable physical dimensions. Thereafter, the concrete floor is marked with a plurality of reference points which establish the critical locations of building elements such as walls or the like. This marking process is, in essence, a process of transferring a portion of the plan information from the building plans to the concrete surface. For many years, the basic approach for marking this layout and reference information upon the concrete floor surface employed a manual process. The prints and plans were viewed and understood by one or more operators who utilized a number of measurements to transfer the information from the plans to the concrete floor. In many instances, additional apparatus such as chalk lines or the like were utilized to establish connecting lines between reference points such as connecting straight line wall contours between corner positions. In addition, some systems employed surveyors instruments to establish critical location points upon the concrete floor.
With the development of complex and evermore capable digital information systems, practitioner's in the art began utilizing computer generator plans for building design rather than the previously established blue print type plans. In such systems, the plan information is created in accordance with a design software which then stores the plan information in digital file form. Once created as digital files, even the most complex plans and extensive building designs may be processed, transferred, stored and transported with great efficiency as digital data. As technology advanced and capabilities of ever smaller computing systems evolved, such building plans were easily storable and transferrable within handheld communication devices. This advance provided substantial improvement in the efficiency of the construction layout process in that the entire building plan set was easily transportable to the build site. As the build site, operators were able to utilize the plans employing the handheld digital devices by virtue of the display screens which such devices provided.
Perhaps one of the most popular and effective electronic layout systems currently employed is the TRIMBLE MEP system sold by TRIMBLE INCORPORATED. Systems such as the TRIMBLE MEP system make use of the recent developments in digital electronic systems which facilitate the position locationing of one element of a communication system relative to a base system unit. Thus, system such the TRIMBLE MEP system provide a base unit which stores plan layout information within an internal memory. The base unit is positioned at a reference point previously established in the plan information. The base unit includes positioning and locating systems. The system also includes a prism pole which in turn supports a prism reflector. The system further includes a handheld PDA unit which includes a substantial memory for storing plan information together with communication apparatus constructed to communicate with the base unit in bi-directional communication. The positioning and location system within the base unit is operative to determine the current position of the prism reflector. The base unit communicates location information of the prism reflector relative to the base unit.
In operation, the base unit is positioned at a reference point previously established within the building plans. An operator, often called the marker, carries the prism pole and PDA while walking upon the concrete building floor. As the marker moves about the concrete floor, the position of the prism reflector on the prism pole carried by the marker is tracked and compared to a to-be-marked reference point within the stored plan. The base unit communicates direction information to the PDA unit aiding the marker in reaching the to-be-marked reference point. When the marker carries the handheld unit to the to-be-marked reference point, the base unit confirms the location to the PDA unit and gives the marker confirmation of correct positioning. The marker then marks the location of the reference point upon the concrete. For the most part, the marker typically employs a conventional ink marker, paint marker or the like in establishing reference marks. This process is repeated for the required number of reference points to be established upon the concrete floor of the building. In some instances, reference points are connected by lines utilizing conventional apparatus such as chalk lines or the like. One example of such chalk line use is the creation of wall perimeter sections between reference points.
While systems such as the foregoing described system have enjoyed some success, the use of operators to provide manual positioning and movement of the handheld unit and to mark reference points upon the concrete surface requires and additional operator. Also, the use of a manual positioning operator often subjects the marking system to errors and inconsistencies.
In technologies generally related to the present invention, U.S. Pat. No. 5,671,160 issued to Julian sets forth a POSITION SENSING SYSTEM for three-dimensional position sensing including a target station, a reference station and a means for accurately calculating the position of the target station relative to the reference station. The system includes the use of at least one gyroscope and a computer to determine the position of the target station. The system may be used for land surveying, earth grading, and marine navigation.
In technologies also related generally to the present invention, practitioners in the art have developed various robotic devices such as US Published Patent Application US2009/0228166 filed on behalf of Durkos et al which sets forth a ROBOTIC VEHICLE CONTROLLER providing a system for automatically moving a robotic machine along a desired path. The device is self contained and mobile and includes communication and control apparatus.
U.S. Pat. No. 5,990,809 issued to Howard sets forth an UNDERWATER SURVEYING SYSTEM utilized in surveying the bottom of a shallow body of water having a submersible remotely-controlled self-powered vehicle. The vehicle includes a chassis, a drive mechanism, a drive control module to direct the movement of the vehicle and a mast extending upwardly from the chassis supporting an antenna on the upper portion. Control signals are transmitted from land to the vehicle via the antenna to control movement.
U.S. Pat. No. 4,137,638 issued to Watts sets forth an ELECTROMECHANICAL SURVEY VEHICLE AND METHOD having a multi-wheeled articulated chassis supporting a plurality of rolling wheels and a plurality of position encoders. The movement of the articulated elements of the vehicle is sensed by the plurality of encoders as the vehicle moves providing contour information for the terrain across which the vehicle travels.
U.S. Pat. No. 7,066,276 issued to Wilcox sets forth a METHOD AND APPARATUS FOR EVACUATING EARTH TO A DESIRED DEPTH which includes a robotic self-propelled vehicle having remotely controlled movement apparatus. The vehicle supports an extending mast which includes visual elements utilized in determining the depth of the surface upon which the vehicle is moving. Line of sight visualization of the position of the mast supported visible elements provides depth information.
U.S. Pat. No. D437,255 issued to Bickler et al sets forth a design for a mars rover. The mars rover is self-powered and controlled by control information supplied remotely as the vehicle is deployed upon a remote surface such as the planet Mars or the like.
Despite substantial advances in the arts related to construction site marking and the transfer of plan information, there remains nonetheless a continuing need in the art for ever more improved, effective, and efficient marking systems.
Accordingly, it is a general object of the present invention to provide an improved construction site marking apparatus. It is a more particular object of the present invention to provide an improved construction site marking apparatus which avoids the need for an operator to carry the moveable element in a site marking system.
In accordance with the present invention, there is provided a robotic apparatus for construction site marking upon a floor surface, said robotic apparatus comprising: a base unit positionable at a reference point upon a floor surface having means for storing site layout information, location means and communication means; a movable position locator cooperating with the base unit in communication therewith; a robotic marker having a body, a plurality of drive wheels and a drive controller for operating the drive wheel to move the robotic marker upon a floor surface; a receptacle receiving a portion of the position locator; spray means having a sprayer and a spray nozzle; and a gimble support supporting the position locator and the sprayer such that the position locator and the spray nozzle are aligned along a common vertical axis, the base unit and the position locator cooperating to direct the robotic marker to move to one or more reference points upon a floor surface and to mark a floor at the one or more reference points by activating the sprayer.
The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements and in which:
In the preferred fabrication of the present invention, robotic marker 20 operates under the control of a base unit such as the base unit manufactured by TRIMBLE MEP which in turn is operated utilizing TRIMBLE field software. In further accordance with the preferred fabrication of the present invention and as is described below in greater detail, robotic marker 20 supports a handheld controller also preferably manufactured by TRIMBLE MEP. In accordance with the operation of the TRIMBLE MEP system and software, the TRIMBLE field software imports both 3D point data CAD files into the handheld controller for the location of various reference points and positions such as wall contours and utility apparatus locations. In accordance with the present invention and as is described below in greater detail, robotic marker 20 provides a self-propelled entirely self-sufficient battery powered robotic unit which utilizes the guidance and communication of the TRIMBLE MEP system to facilitate reference marking upon surface 14 of concrete floor 10 without the need for a marking operator. The system is fully self-contained and includes an onboard battery power supply together with differential directional drive apparatus or movement. As is also set forth below in greater detail, robotic marker 20 further includes a receptacle for supporting the handheld TRIMBLE MEP controller together with a spray marker in a gimble supported apparatus. The gimble supported unit is described below in greater detail. However, suffice it to note here that the gimble support of the spray marker and guidance unit apparatus maintains the required perpendicular vertical orientation of the sprayer and guidance unit necessary to maintain accuracy of marker placement. The battery-powered differential drive system utilized in robotic marker 20 may be constructed in accordance with conventional fabrication systems suitable for moving robotic marker 20 upon surface 14 to any desired location or through any desired path.
In accordance with an important aspect of the present invention, body 21 further includes apparatus for supporting a prism pole 40 constructed in accordance with the locating system operating in the manner described above. Thus, in the illustration of the present invention shown in
Apparatus 20 further includes a pair of drive wheels 25 and 26 supported upon body 21 and operatively coupled to a pair of drive motors 71 and 72 respectively. Drive motors 71 and 72 are operative in accordance with conventional fabrication techniques to provide bi-directional differential rotational power to drive wheels 25 and 26 to facilitate movement and turning of apparatus 20 upon surface 14. As is also described above, apparatus 20 further supports a prism pull 40 having a prism reflector unit 41 on the upper end of a supporting staff 42. Staff 42 also supports PDA 76 and extends downwardly into body 21 and is protectively enclosed by a flexible boot 43 secured to upper surface 24. Cable 75 operatively couples PDA 76 to the control system within body 21 (seen in
Apparatus 20 further includes an electronic gimble apparatus 50 which is secured within body 21 to provide a gimbled attachment to a staff receptacle 55 and a sprayer 56. Staff receptacle 55 and sprayer yoke 56 are physically joined in an axial alignment and are secured to the gimbled support of gimble 50. While it will be recognized that a plurality of gimbles suitable for supporting receptacle 55 and sprayer yoke 56 in a vertical orientation are available in the art. It has been found advantageous to utilize a digital gimble servo motor controlled gimble assembly manufactured by Robotzone, LLC which utilizes a pair of rotational supports operative on two different axes to maintain a vertical orientation for staff receptacle 55 and sprayer yoke 56. The structure of gimble 50 is set forth below in
More specifically, gimble 50 includes a generally L-shaped frame 54 having a first servo 90 supported within one end of frame 54 includes a servomotor having an output shaft (not shown) coupled to a plate 91. Plate 91 is secured to wall portion 29 of apparatus body 21 utilizing fastener attachment or other convenient attachment and in accordance with conventional fabrication techniques. With plate 91 secured to wall portion 29, the remaining apparatus which forms gimble 50 is supported without additional attachment to a supporting wall or surface. Gimble 50 further includes a second servo 92 having a servomotor supported within frame 54 which in turn includes an output shaft (not shown) coupled to an output plate 93. Plate 93 in turn supports an extending band 61.
As mentioned above, staff receptacle 55 and sprayer yoke 56 are joined in accordance with conventional fabrication techniques in axial alignment. Thus, band 61 is secured to staff receptacle 55 and sprayer yoke 56 in a secure rigid attachment. Sprayer yoke 56 supports sprayer 30 which includes a downwardly extending spray nozzle 32 and a plurality of material and air couplings 33, 34 and 35. Couplings 33 through 35 are utilized in coupling sprayer 30 to spray controller 57 (seen in
In further accordance with the present invention, receptacle 55 receives the lower end of staff 42 of prism poll 40. Staff 42 defines a conical lower end 47 and further supports prism reflection unit 41 at its upper end.
In accordance with an important aspect of the present, the lower end of staff 42 is received within staff receptacle 55 by forcing it downwardly in the direction indicated by arrow 48. This downward movement of the lower end of staff 42 flexes shims 53 outwardly against the interior wall of bore 52. Shims 53 provide secure tight attachment between receptacle 55 and the lower end of staff 42. In addition, shims 53 cooperate to precisely center and position staff 42 within respect to the axis of staff receptacle 55. In this manner, prism reflection unit 41 of prism poll 40 and staff 42 are maintained in alignment with the axis of staff receptacle 55, sprayer yoke 56 and sprayer 30. For purposes of illustration, this axis is shown and referenced as axis 67. Once again, it must be understood that the importance of this alignment is the accurate positioning of spray nozzle 32 of sprayer 30 in vertical alignment with prism reflection unit 41. This ensures that the position information communicated within the positioning system is equally applicable of the position of spray nozzle 32. This in turn ensures accurate placement of sprayed marking elements produced when the system operates upon a concrete floor or the like.
In operation, gimble controller 51 (seen in
More specifically, in response to orientation signals provided by gimble controller 51, servo 90 is operative to rotate frame 54 about axis 86 in the manner indicated by arrows 81. This rotation in turn produces rotation of sprayer yoke 56 and receptacle 55 about axis 86 in the manner indicated by arrows 85. Additionally, signals from attitude sensor 94 processed by gimble controller 51 are also applied to servo 92. Servo 92 is operative to rotate plate 93 about axis 84 in the directions indicated by arrows 82. This in turn rotates band 61 and the combination of sprayer yoke 56 and staff receptacle 55 about axis 84 in the directions indicated by arrows 83. The combined action of servos 90 and 92 produces two directional rotation of the combination of sprayer 30, sprayer yoke 56, staff receptacle 55 and staff 42 in both directions to maintain axis 67 in a vertical orientation perpendicular to the supporting surface upon which apparatus 20 is operating.
More specifically,
Once the system checks performed in steps 102 through 126 have been successful, the system moves to initiate a setup routine at step 127. At step 127, the setup routine or initialization of the operative system is carried forward. Following the entrance of the setup routine at step 127, the system moves to step 128 in which point data information is retrieved from the base unit. Thus, following step 128, the system moves to step 129 establishing communications with the RTS afterwhich the system displays data for user selection at step 130. Display of data is carried forward by display upon control panel 23 (seen in
Following successful implementation of steps 138 through 140 as indicated at step 141, the system moves to initiate its start routine at step 144. The start routine initiated at step 144 performs an RTS test at step 145, and thereafter moves to step 146 in which the robotic marker is commanded to move to the first reference point. Once location at first reference point is confirmed, the system moves to step 147 in which the sprayer is activated. In some instances, a sprayer activation will not be required at a given reference point. Following step 147, the system then commands the robotic unit at step 148 to proceed to the next reference point location. At step 149, the location at the next reference point is confirmed and the sprayer unit is again activated (if required) at step 149. Thereafter at step 150, the system logs any errors or problems encountered in moving to and between the reference points. At step 151, a determination is made as to whether the reference point at step 148 was the final reference point in the point data files. In the event the reference point at step 148 is not the final reference point of the routine, the system returns to step 148 and commands the robotic marker to move to the next reference point. Thereafter, the system moves again through steps 149 and 150 continuing to cycle therethrough until a determination is made at step 151 that the last reference point has been processed.
Following the determination at step 151 that all data point have been processed, the system moves to an end routine 152. At steps 153, the robotic marker is commanded to return to the starting point and, at step 154, the marking routine results are display and the information derived during the marking routine is logged in. Thereafter, the system reaches the end of the operative cycle at step 155 and ceases further operation until a start command is initiated again at step 100.
What has been shown is a novel robotic construction site marking apparatus which cooperates with a suitable location and positioning apparatus having a base unit and a movable handheld position detecting apparatus. The inventive system provides means for supporting and carrying the mobile portion of the host system upon the surface of a construction site such as a concrete floor. The system provides a cooperating gimble support for the location apparatus and a controlled sprayer for marking the host surface under the control of communicated reference point information. A robotic construction site marking apparatus includes a self-propelled robotic marker which carries the mobile location element and the marking sprayer under data control of the base system. The accuracy of spray marking location is ensured by the accurate gimble support of the sprayer and the sensing portion of the mobile positioning unit in an aligned vertical orientation.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
