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Improvement of the mobile robot location dedicated for habitable house construction by 3D printing
Proceedings,16th IFAC Symposium on Proceedings,16th IFAC Symposium on Information Control Problems in Manufacturing Proceedings,16th IFAC Symposium on Information Control Problems in Proceedings,16th IFAC Symposium on Bergamo, Italy, June 11-13, 2018 Information Control Problems in Manufacturing Manufacturing Available online at www.sciencedirect.com Bergamo, June 11-13, 2018 Proceedings,16th IFAC Symposium on Information Control Problems in Manufacturing Bergamo, Italy, Italy, June 11-13, 2018 Information Control in Manufacturing Bergamo, Italy, JuneProblems 11-13, 2018 Bergamo, Italy, June 11-13, 2018
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IFAC PapersOnLine 51-11 (2018) 716–721
Improvement of the mobile robot location Improvement of the mobile robot location Improvement of the mobile robot location Improvement of the mobile robot location dedicated for habitable house construction dedicated for habitable house construction Improvement of the mobile robot location dedicated for habitable house construction dedicated for by habitable house construction 3D printing 3D printing dedicated for by habitable house construction by by 3D 3D printing printing K´ evin Subrin, by Thomas S´ ebastien Garnier, 3D Bressac, printing K´ evin Subrin, Thomas Bressac, S´ ebastien Garnier,
K´ evin Subrin, ThomasElodie Bressac, S´ ebastien Garnier, Alexandre Ambiehl, Paquet, Benoit Furet K´ evin Subrin, ThomasElodie Bressac, S´ ebastien Garnier, Alexandre Ambiehl, Paquet, Benoit Furet Alexandre Ambiehl, Elodie Paquet, Benoit Furet K´ e vin Subrin, Thomas Bressac, S´ e bastien Garnier, Alexandre Ambiehl, Elodie Paquet, Benoit Furet LS2N Alexandre (Laboratory of Digital Sciences of Nantes), Nantes University, Ambiehl,Sciences Elodie of Paquet, Benoit Furet LS2N (Laboratory of Nantes University, LS2N (Laboratory Institutes of Digital DigitalofSciences of Nantes), Nantes), Nantes University, IUT (University Technology), 2 av. Prof. Jean Rouxel LS2N (Laboratory of France Digitalof Sciences of Nantes), Nantes University, IUT (University Institutes Technology), 2 Jean Rouxel IUT (University Institutes of Technology), 2 av. av. Prof. Prof. Jean Rouxel 44470 Carquefou, (e-mail: [email protected]) LS2N (Laboratory of France Digital (e-mail: Sciences of Nantes), Nantes University, IUT (University Institutes Technology), 2 av. Prof. Jean Rouxel 44470 Carquefou, [email protected]) 44470 Carquefou, France of (e-mail: [email protected]) IUT (University Institutes Technology), 2 av. Prof. Jean Rouxel 44470 Carquefou, France of (e-mail: [email protected]) 44470 building Carquefou, France (e-mail: [email protected]) Abstract: Currently, construction is beginning to consider the use of 3D printing which Abstract: Currently, building construction is consider the 3D Abstract: Currently, building construction is beginning beginning toproven consider the use use of oftechniques. 3D printing printingAwhich which can be considered as an evolution or modernization of itsto traditional new Abstract: Currently, building construction is beginning to consider the use of 3D printing can be considered as an evolution or modernization of its proven traditional techniques. A new can be considered as anapproach evolution(Foam or modernization of its proven traditional techniques. Awhich new process based on FAM Additive Manufacturing) has been patented by Nantes Abstract: Currently, building construction is beginning toproven consider thebeen use of 3D printing which can be considered as an evolution or modernization of its traditional techniques. A new process based on FAM approach (Foam Additive Manufacturing) has patented by Nantes process based onwall FAMmanufacturing approach (Foam Additive Manufacturing) haspolyurethane been patentedfoam by Nantes University. The is based on the laying of two beads can be considered as an evolution(Foam or modernization of laying its proven traditional techniques. Abeads new process based onrole FAM approach Additive has been patented by Nantes University. The wall manufacturing based on the two polyurethane University. The wall manufacturing isthe based on Manufacturing) the laying ofand two polyurethane foam beads which the of framework foris concrete and insideof outside thermalfoam insulation. processplays based onrole FAM approach (Foam Additive Manufacturing) has been patented by Nantes University. The wall manufacturing is based on the laying of two polyurethane foam beads which plays the of framework for the concrete and inside and outside thermal insulation. which plays the of framework for the concrete and architecture inside and outside thermal insulation. To perform the role laying, the development of aonrobotic integrates an foam automated University. The wall manufacturing based the laying ofand twooutside polyurethane beads which plays the role of framework foristhe concrete and inside thermal insulation. To the laying, the of architecture integrates an To perform perform theand laying, the development development of aa robotic robotic architecture integrates an isautomated automated guided vehicle an industrial robot located on it. The printing environment complex: which plays the role of framework for the concrete and inside and outside thermal insulation. To perform laying, the of robot a robotic architecture guided vehicle and an industrial robot located on it. printing environment is complex: guided vehicle and an industrial robot slab, located onhoses, it. The The printing environment isautomated complex: printed walls,the pipes inside thedevelopment concrete house form integrates complexity,an steel To perform the laying, the development of robot a robotic architecture integrates anvertical automated guided vehicle and an industrial robot located on it. The printing environment is complex: printed walls, pipes inside the concrete slab, hoses, house form complexity, vertical steel printed walls, pipes inside the concrete slab, robot hoses, house form complexity, vertical steel reinforcement. Also, the concrete slab inspection shows a flatness defect close to 25mm (regular guided vehicle and an industrial robot located onhoses, it. aThe printing environment is complex: printed walls, pipes inside the concrete slab, robot house form complexity, vertical steel reinforcement. Also, the concrete slab inspection shows flatness defect close to 25mm (regular reinforcement. Also, thethe concrete slab inspection shows a flatness defect close to 25mm (regular defect) which impacts robot accuracy. The objective is then to find the best location for printed which walls, pipes the concrete slab,The robot hoses, house form complexity, vertical steel reinforcement. Also, inside the concrete slab inspection shows a flatness defect to 25mm (regular defect) impacts the robot accuracy. objective is then to the best location for defect) which impacts the robot accuracy. The to objective isthe then to find findclose the best location for an AGV (Automated Guided Vehicle) in order perform printing in the best conditions. reinforcement. Also, the concrete slab inspection shows a flatness defect close to 25mm (regular defect) which impacts the robot accuracy. The objective is then to find the best location for an AGV (Automated Guided Vehicle) in order to perform the printing in the best conditions. an AGV (AutomatedonGuided Vehicle) in order to performfor thehouse printing in the best conditions. After a comparison current mobile robot architecture manufacturing, we present defect) impacts the robot accuracy. The objective isthe then to findinthe location for an AGV (Automated Vehicle) in order to perform printing thebest bestnavigation conditions. After aa which comparison on current mobile robot architecture for house we After comparison onGuided current mobile robot architecture for house manufacturing, we present present the location of the mobile robot in its environment where, during themanufacturing, firstinday, is an AGV (Automated Guided Vehicle) in order to perform thehouse printing the the bestnavigation conditions. After a comparison on current mobile robot architecture for manufacturing, we present the location of the mobile robot in its environment where, during the first day, the the location the improved mobile robot in its environment where, Via during first day, the navigation is is analysed andofthen to perform the house printing. the the homogeneous transformation, After a comparison on current mobile robot architecture for house manufacturing, we present the location ofthen the improved mobile robot inModel its environment where, Via during the first day, the navigation is analysed and to the house printing. the homogeneous transformation, analysed and then improved to perform perform the house printing. Via theto homogeneous transformation, we outline the Direct Geometrical and our implementation improve the accuracy of the theoutline location of Direct the improved mobile robot inModel its environment where, Via during the first day, the navigation is analysed and to perform house the homogeneous transformation, we the Geometrical and our implementation to improve accuracy of we outline thethen Direct Geometrical Model and our printing. implementation to improve the accuracy of the the robotic system. Finally, we present the the manufacturing principle and the finalthe result: a habitable analysed and then improved to perform the house printing. Via the homogeneous transformation, we outline the Direct Geometrical Model and our implementation to improve the accuracy of the robotic system. Finally, we present the manufacturing principle and the final result: a habitable roboticbysystem. Finally, we present the manufacturing principle and the final result: a habitable house 3D we outline theprinting. Direct Geometrical and our implementation to improve accuracy of the robotic Finally, we presentModel the manufacturing principle and the finalthe result: a habitable house 3D house by bysystem. 3D printing. printing. robotic system. Finally, weFederation present the manufacturing and the final a habitable house 3D (International printing. © 2018,by IFAC of Automatic Control)principle Hosting by Elsevier Ltd.result: All rights reserved. Keywords: Mobile robot, 3D printing, Accuracy improvement, Automated Guided Vehicle, house by 3D printing. Keywords: Mobile robot, Accuracy improvement, Keywords: Mobile robot, 3D 3D printing, printing, Accuracy improvement, Automated Guided Guided Vehicle, Vehicle, Foam Additive Manufacturing, Building Information ModelingAutomated Keywords: Mobile robot, 3D printing, Accuracy improvement, Automated Guided Vehicle, Foam Additive Manufacturing, Building Information Modeling Foam Additive Manufacturing, Building Information Modeling Keywords: Mobile robot, 3D printing, Accuracy improvement, Foam Additive Manufacturing, Building Information ModelingAutomated Guided Vehicle, 1. USE OF Foam ROBOTIC ARCHITECTURE FOR HOUSE otherModeling sectors. Its frequency index, representing the number Additive Manufacturing, Building Information 1. FOR sectors. Its representing the number 1. USE USE OF OF ROBOTIC ROBOTIC ARCHITECTURE FOR HOUSE HOUSE other other sectors.with Its frequency frequency index, representing the reached number 3D ARCHITECTURE PRINTING of accidents interruptindex, for 1000 employees, 1. USE OF ROBOTIC ARCHITECTURE FOR HOUSE other sectors. Its frequency index, representing the number 3D PRINTING of accidents with interrupt for 1000 employees, reached 3D PRINTING of accidents with interrupt for 1000 employees, reached 93.98 while the mean is 39.40 for all activity sectors. These 1. USE OF ROBOTIC FOR HOUSE 93.98 other sectors. Itsmean frequency index, representing the reached number 3D ARCHITECTURE PRINTING of accidents with interrupt for 1000 employees, while the is for all activity sectors. These 93.98 while the mean is 39.40 39.40 for all activity sectors. These values are quite old but it still reflects a set of expectancy. 1.1 Introduction 3D PRINTING of accidents with interrupt for 1000 reached 93.98 while the mean is 39.40 for all activity sectors. These values are quite old but it still reflects aaemployees, set of expectancy. 1.1 Introduction values are quite old but it still reflects set of expectancy. 1.1 Introduction 93.98 while the mean is 39.40 for all activity sectors. These To perform 3D construction, weof observe many values are quite oldprinting but it still reflects a set expectancy. 1.1 Introduction perform the 3D printing construction, we observe many Currently, building construction is beginning to seriously To values are quite old but it still reflects aall, set of expectancy. To perform the 3D printing construction, we observe many 1.1 Introduction aspects to reach the objectives. First of the final results Currently, construction is To perform the 3D printing construction, we observe many to reach the objectives. First of all, the final results Currently, building construction is beginning beginning to seriously consider thebuilding use of 3D printing (Labonnote et to al.seriously (2016)). aspects aspects to reach the objectives. First of all, the final results (house) have to be approved by certified organism (CSTB Currently, building construction is beginning to seriously consider the use of 3D printing (Labonnote et al. (2016)). To perform the 3D printing construction, we observe many aspects to reach the objectives. First of all, the final results (house) have to be approved by certified organism (CSTB consider the use of 3D printing (Labonnote et al. (2016)). Despite thebuilding reluctance of technical complexity (increase (house) have to Technical be approved by certified organism and Centre forofBuilding) as(CSTB far as Currently, construction is beginning to seriously consider theskills, use ofredefinition 3D printing (Labonnote et procedures) al.(increase (2016)). (Scientific Despite the reluctance of complexity aspects to reach theapproved objectives. First all,organism the final results (house) have to be by certified (CSTB (Scientific and Technical Centre for Building) as far as Despite the reluctance of technical technical complexity (increase of technical of construction (Scientific and Technical Centre for Building) as far as concerned). Before the house, a set consider the theskills, use ofredefinition 3D printing (Labonnote et procedures) al.(increase (2016)). France Despite reluctance ofthe technical complexity of of (house) is have to Technical be approved bybuilding certified organism (CSTB (Scientific and Centre for Building) as far as France is concerned). Before building the house, a set of technical technical skills, redefinition of construction construction procedures) and social (reduction of number of workers, replaceFrance Before building the house, of a the set of proveisOfconcerned). concept characterizes the Building) performance Despite the(reduction reluctance of technical complexity (increase of skills, redefinition of many construction procedures) and social of of workers, replace(Scientific and Technical Centre for as far as France isOf concerned). Before building the house, a the set prove concept characterizes the performance of andtechnical social (reduction of the the number number oftechnical workers, replace- of ment of humans by machine), solutions of prove Of concept characterizes the performance of the automated constructions systems in order the house to be, of technical skills, redefinition of construction procedures) and social (reduction of the number of workers, replacement of humans by machine), many technical solutions France is concerned). Before building the house, a set of prove Of concept characterizes the performance of the automated constructions systems in order the house to be, ment of humans by machine), many technical solutions are at increasing speed and more and morereplaceactors once automated constructions systems order system the house to be, finished, insured.characterizes Finally, the in robotic performs andgrowing social (reduction of the number oftechnical workers, ment ofconstruction humans by sector machine), many solutions are growing at speed and more and actors of prove Ofconstructions concept the performance of the automated systems in order theworking house towith be, finished, insured. Finally, the robotic system performs arethe growing at increasing increasing speed and more and more more actors once in (architects, builders, building once finished, insured. Finally, the robotic system performs the activities while being safe for people ment ofconstruction humans by sector machine), many technical solutions are growing at increasing speed and more and more actors in the (architects, builders, building automated constructions systems in order the house to be, once finished, insured. Finally, the robotic system performs activities while being safe for people working with in the construction sector (architects, builders, building the owners) are interested in these new solutions. In addition, theTo activities while being safe for people working with presentinsured. the proposed approach, wesystem review robotic arethe growing at increasing speed and solutions. morebuilders, and In more actors it. in construction sector (architects, building owners) are interested in these new addition, once finished, Finally, the robotic performs the activities while being safe for people working with it. To present the proposed approach, we review robotic owners) are interested in these newused solutions. In manufacaddition, architecture the construction sector has always additive it. To present thefor proposed approach, we review robotic used house safe 3D printing. Then, we present in the construction sector (architects, builders, building architecture owners) are interested these newused solutions. In addition, the sector has always additive manufactheTo activities while being for people working with it. present the proposed approach, we review robotic used for house 3D printing. Then, we present the construction construction sectorin has always used additive manufacturing (brick, concrete, stone, sandstone) and 3D printing architecture used for house 3D printing. Then, we present the constraints on the process and the robotic architecture. owners) are interested these newused solutions. In addition, the construction sectorin has always additive turing (brick, concrete, stone, sandstone) and 3D printing it. To present the proposed approach, we review robotic architecture used for house 3D printing. Then, we present constraints on the process and the robotic architecture. turing (brick, concrete, stone, sandstone) and 3Dmanufacprinting the of buildings is therefore only an evolution or modernization the constraints onofthethe process and the robotic architecture. complexity environment shows that finding thebuildings construction sector only has always used additive turing (brick, concrete, stone, 3Dmanufacprinting The of is an evolution modernization architecture used for house 3Dand printing. Then, we present the constraints onof the process thenot robotic architecture. The complexity the environment shows that finding buildings is therefore therefore only ansandstone) evolution or orand modernization of proven traditional techniques. The complexity of the environment shows that finding a location for the mobile robot is so easy while we turing (brick, concrete, stone, sandstone) and 3D printing is therefore only an evolution or modernization aThe of proven techniques. thelocation constraints onofthe process and isthenot robotic architecture. complexity the environment shows that finding for the mobile robot so easy while we of buildings proven traditional traditional techniques. a location for the mobile robot is not so easy while we a defect flatness on the concrete slab. Our result is therefore only evolution modernization From an economic point of an view, we areorobserving rising observe of buildings proven traditional techniques. The complexity of mobile the environment shows that finding a location for the robot is not so easy while we observe a defect flatness on the concrete slab. Our result From an economic point of view, we are observing rising observe a defect flatness on the concrete slab. Our result shows how we characterize the location of the robot and of proven traditional techniques. From an economic point of view, we are observing rising construction costs (new construction standards,...) with shows a location for the mobileonrobot is not so easy whileand we observe a defect flatness thehouse. concrete we the location of the robot From an economic point construction of view,According we are observing rising construction costs standards,...) with showswehow how we characterize characterize the location ofslab. the Our robotresult and improve it to print the construction costs (new (new construction standards,...) with how significant occupational risks. to the INRS observe a defect flatness on the concrete slab. Our result shows we characterize the house. location of the robot and how improve it From an economic point construction of view,According we are observing rising construction costs (new standards,...) with significant occupational risks. toaccounts the INRS INRS how we wehow improve it to to print print the the house. significant occupational risks. According to the (Tissot (2010)), in 2007, the building sector for how showswehow we characterize the house. location of the robot and improve it to print the construction costs (new construction standards,...) with significant occupational risks. According to the INRS (Tissot (2010)), in 2007, the building sector accounts for (Tissot in 2007, the building 8.6% of (2010)), all occupational employees in France. This sectortoaccounts for how we improve it to print the house. significant risks. According the INRS (Tissot in with 2007, the building sector accounts 8.6% all employees in France. This 8.6% of ofof(2010)), all employees ininterrupt, France. This sector accounts for for 18.2% accidents 20.7% of accidents (Tissot (2010)), in with 2007, the building sector accountswith for 8.6% of all employees in France. This 18.2% of accidents interrupt, 20.7% of accidents with 18.2% of accidents with interrupt, 20.7% of accidents with permanent disability and 29.6% of deaths compared to 8.6% ofofall employees ininterrupt, France. This sector accountswith for 18.2% accidents with 20.7% of accidents permanent disability and 29.6% of deaths compared permanent disability and 29.6% of deaths compared to to 18.2% of accidents with interrupt, 20.7% of accidents with permanent disability and 29.6% of deaths compared to Copyright © 2018, 2018 IFAC permanent disability and 29.6%Federation of deaths compared to723Hosting by Elsevier Ltd. All rights reserved. 2405-8963 © IFAC (International of Automatic Control) Copyright © 2018 IFAC 723 Copyright 2018 responsibility IFAC 723Control. Peer review©under of International Federation of Automatic Copyright © 2018 IFAC 723 10.1016/j.ifacol.2018.08.403 Copyright © 2018 IFAC 723
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Fig. 1. Contourcrafting(a), Winsun(b), FastBrick Construction(c), Construction 3D(d), MX3D(e), MIT robot(f) 1.2 State of the art
Today, companies and research laboratories search future market aiming at building construction via automated processes (Fig. 1). The architectures used for the laying of material are generally cartesian (Contourcrafting (Khoshnevis (2004)) where we observe a rail on which a structure and a crossbar allow the 3D printing (Fig. 1a). In the same way, Winsun3d (Winsun (2015)) proposes an architecture where the structure can be tilted (Fig. 1b). Other approaches focus on a mobile robot with telescopic arm in order to lay out bricks such as Fastbrick Robotic Construction (FastBrickConstruction (2016))(Fig. 1c) to lay out foam such as MIT solution (Keating et al. (2017))(Fig. 1f) or to lay out concrete (Construction3D (2017))(Fig. 1d). These architectures are heavy with several tons of equipment. Other approaches are currently being conducted via industrial robots using a print head for the deposit of fusion wire (Jokic et al. (2014))(Fig. 1e) or by welding processes such as the addition of metal by fusion (MX3D (2017)). The latter approach, led by the firm MX3D became known by the manufacture of a bridge using two robots that move on what they have built. All of these architectures denote the high activity on this topic. The construction time is decreased via a better management of the manufacturing process. In addition, the tough activity is partly devolved to the robotic means; thus, the difficulty of the activity is greatly reduced. In addition, with the digitalization of the activity, it is then possible to improve the construction flow of buildings. However, the emergence of these new means puts forward difficulties concerning the implementation of these processes on site and the investment of the means of printing with the associated training. The implementation of these new processes aims to redesign the principles of construction. Principles, morphologies, kinematics of the robotic system, processes (material,...) allow to redefine the know-how : new architectural design can be envisioned. 724
Fig. 2. Innoprint3D project where a shelter has been built 2. 3D PRINTING WITH A MOBILE ROBOT In the next section, we present the Foam Additive Manufacturing and the manufacturing process which has been used to manufacture the habitable house. 2.1 Foam Additive Manufacturing and constraints on the process FAM or Foam Additive Manufacturing technology is a marriage between additive foam manufacturing and topological optimization for 3D printing of large parts. In order to develop additive manufacturing skills for large dimensions, the University of Nantes has led various developments that have been materialized by a demonstrator called INNOPRINT3D. The robotic 3D printing of a shelter made of polyurethane foam (1.75mx1.75mx2.5m) is built up in 30min only. An industrial robot deposits foam which in contact with the air is expanded from 30 to 45 times its volume. The main challenge concerns the trajectory management with the expansion of the foam to print the unsupported roof. After analyzing these first results and summarizing previous work, several patents which protect the intellectual properties of the solution have been submitted (figure 3). This building principle makes it possible to quickly print all types of construction walls with flat or even complex geometries. Regarding existing self-supported insulated
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formwork elements which are commercially available, this new process gives a freedom in shape. Moreover, it combines several trades such as masons and insulation. This work named Batiprint3D project has been supported by the University of Nantes, the SATT Ouest Valorisation and several companies. It focuses on the realization of a ”social housing”. Then, as a second step, we developed a 3D printing solution for single-family buildings by creating an exploitable means directly on site. To do this, we have decomposed our development into three areas of research: process (developed in this paper), formulation (Concrete and foam properties) and characterization (materials behaviors of the house).
well manage the Tool Center Point of the industrial robot in its environment.
Fig. 5. Yhnova concrete slab floor flatness defect in mm 2.2 Architecture of the mobile robot
Fig. 3. Patent where the concrete is deposited between two layers of foam that serve as framework The main issue is the combination of a tool (mobile and articulated robot) with a material (Polyurethane and concrete) allowing the realization in situ of the wall. To do this, the tool must be transportable, adapted to the external environmental constraints of the construction site and stable to allow injection of the material without significant performance tolerance. From the digital model of the house performed by an architect, the house edge is cut to generate 28 areas where the robot accessibility enables us to print. Once the slab is ready (figure 4), our robotic solution prints it on the building site (structure and insulation), and once the elevation of the walls is completed, the mobile robot emerges through an opening. The house which has been printed is 95m2 . The walls are 4m high.
The mobile robot includes an Automated Guided Vehicle (AGV) and an industrial robot. The Automated Guided Vehicle is a BA Systems robot with safety laser scanners. This robotic system, following the odometry it uses, offers good performances in terms of accuracy inside large space (10mm) (Vasiljevi´c et al. (2016), Ronzoni et al. (2011)). A set of reflectors is positioned around the concrete slab floor to manage the location of the AGV (figure 6). A lifter allows to raise the Staubli Industrial robot. On the platform, the robot controller and a set of counterweight allow to use the mobile robot in a safe manner. 3. MODELING AND IDENTIFICATION OF THE MOBILE ROBOT The location improvement is based on the management of the mobile robot. A set of constraints (printed walls, pipes inside the concrete slab, robot hoses, house form complexity, vertical steel reinforcement, floor horizontality) are taken into account during the first layers. We present the notation we use to implement a correction matrix taking into account the inclination of the AGV. Corrections matrixes allow to define the position of the Tool Center Point
Fig. 4. Yhnova concrete slab floor With a laser tracker whose measurement accuracy is below 0.01mm, the flatness of the floor has been measured: it exists a flatness defect of 25.2mm (figure 5) which is inside the tolerance we can expect from such a floor. In this way, the mobile robot is equipped with two inclinometers to 725
Fig. 6. Laser scanner and the reflectors for the robot navigation
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AHouseT CP = AHouseAGV ∗ AAGV P sinav ∗ AP sinavLif ter ∗ ALif terRobot ∗ ARobotW rist ∗ AW ristT CP (1) This equation is theoretical and it must be included a correction due to the flatness of the floor. The AGV location given by the AGV software considers the position of the Psinav inside Ohouse Xhouse Yhouse Zhouse which is the point A located at 4m high. To take into account the flatness, two inclinometers have been installed following Zpsinav to detect the rotation of the mobile robot around XAgv and YAgv . The correction is a homogenous matrix which integrates the values of P itch and Roll. Taking into account the flatness, the description of the point inside the robot frame Drobot Xrobot Yrobot Zrobot is Fig. 7. Robot frames
−1 x ARobotT CP = A−1 Lif terRobot ∗ AP sinavLif ter ∗ R (P itch)
(TCP). In our case, we independently manage the AGV and the industrial robot. All the corrections are implemented inside the programming of the industrial robot. Next, we present a set of results to highlight the research of the best location to print the walls.
−1 ∗ Ry (Roll) ∗ A−1 AGV P sinav ∗ AHouseAGV
(2)
3.3 Toward the improvement of the location of the AGV We present here the different issues which permit the location improvement of the AGV.
3.1 Notation Homogeneous transformation are introduced where Aij represents the position and the orientation of a coordinate system j (Oj xj yj zj ) regarding to a coordinate system i (Oi xi yi zi ) (Dombre and Khalil (2002)). 3.2 Modeling of the mobile robot The direct geometrical model allows to define the positing of the TCP following the joint position. This architecture is kinematically redundant with 4 Degrees of Freedom (DoFs) as far the AGV is concerned (θpsi , Xpsi , Ypsi , Zpsi ) and with 6 DoFs (q1 ,...,q6 ) as far the industrial robot is concerned. Two systems are considered and their management is independent. The path that the robot must follow is defined in the frame Ohouse Xhouse Yhouse Zhouse . To print the wall, the AGV stays fixed inside Ohouse Xhouse Yhouse Zhouse . We consider first the position of the frame Drobot Xrobot Yrobot Zrobot which takes into account the flatness of the floor. Then, we consider the position of the TCP inside the robot frame. The AGV location is defined inside the house frame. The Psinav (safety laser scanner for the location) scans a set of reflectors around the house. This scan permits the definition of a virtual point FAGV . The definition by the AGV controller of the location does not take into account the flatness of the floor. We fixed 2 inclinometers to determine the pitch and roll of the Automated Guided Vehicle. The location returned by the AGV software is the frame BAgv XAgv YAgv ZAgv . Following the way to define it, it does not consider the flatness defect. A rigid transformation is so considered (Equation 1).
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Printed wall detection In order to print the wall, 28 working bases were defined to print house walls. Each working base is located inside two vertical reinforcement. Their location is not so easy to define due to the scanner located at the basis of the AGV. This type of AGV focuses more its activity on the carrying of loadings inside warehouse. This scanner permits the navigation and it stops the AGV when an obstacle is detected. In our case, it detects the printed wall and we were not able to be too close to the printed wall. Robot Hoses In order to be able to print, various hoses are fixed to the end effector. Cable carriers allow to manage the travel of the lifter. Then, a set of electric and hydraulic wires permits the printing. The position of this hoses is important to be able to use the robot in a large workspace. House form complexity In order to print large foam bead, the printing takes place on the side of the AGV. The dimensions of the AGV (1.6m length * 1m wide) are quite important and to be able to print the extremity of the house (working base 5 to 7 and 24 on figure 8), robot hoses, dummies (wood structure which represents windows, doors), AGV turning radius and safety laser scanner detection complexifies the research of a good location. Vertical steel reinforcement To respect building norm, vertical steel reinforcement was inserted inside the wall. Each one was hand-positioned. We played a set of trajectories without printing to ensure the collision avoidance. Floor flatness This aspect is taken into account with the two inclinometers. We present in the following section the accuracy improvement with this instrumentation denoting its importance.
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Fig. 9. Location error at 4m high due to angling between two working bases the industrial robot programm to ensure the continuity of the trajectory between two working bases. The house was printed in 54 hours (33 hours theoretically of 3D printing) during september 2017. The thermal properties highlights that such a construction replies to RT 2012 french norm and is 30% better as expected.
Fig. 8. AGV Location during the first day to simulate the printing (a) and AGV location during the printing (b) Labels are in mm Location improvement During all the printing, the AGV location was registered (Figure 8). Label X and label Y represent the cartesian position of the AGV in mm. 28 wall sections depending on their length, geometry (curves, corners) define 28 working bases. We highlight 3 areas named Z1, Z2 and Z3. Z1 area is really interesting due to the fact that we observed a significant defect of flatness here (figure 5). In order to ensure the printing quality, we analyze the difference of angling between two working bases. Figure 9 presents the location error induced by the angling difference between two working bases and show that without inclinometers, at 4m high, we would have an offset of 60mm between the two printing areas. This result shows the accuracy improvement of the mobile robot. Z2 area had a different problematic due to the presence of a common wall. The location of the AGV was important to be able to print as close as possible to the wall. Finally, Z3 presents another complexity of the architecture: a short wall between two vertical steel reinforcement due to the presence of the main door. Various tests allow to define the best AGV location to print the wall. 4. CONCLUSION AND PERSPECTIVES
In this paper, we presented the house building with a new and patented process based on Foam Additive Manufacturing. The integration of such a complex system has an impact on the AGV location and following the flatness of the concrete slab in the higher position of the lifter, an offset up to 60mm must be corrected. To solve the issue, a correction matrix has been implemented to relocate the industrial robot while ensuring the feasibility of the trajectory. The house building is a first step to highlight the potential of such a process (Figure 10). As a perspective, it will be convenient to study the dynamical behavior in order to improve the process speed. As a prototype, the laying dynamic was smooth. It is important, regarding the activity sector, to reach a reliable and efficient solution. 5. ACKNOWLEDGEMENT We acknowledge Nicolas Houssais. We acknowledge Philippe Poulain from GeM laboratory at IUT Saint-Nazaire We acknowledge the support of the following companies : BA Systems, Bouygues Batiment, LafargeHolcim, CSTB, CNRS, Nantes University, SATT Ouest Valorisation, Caisse des d´epots, Nantes M´etropole, Nantes m´etropole Habitat. More details on the house building is available on the website http://www.batiprint3d.fr/ REFERENCES
As a result, we present the different phases which led to the house building. First of all, based on the BIM (numerical definition of the house to be printed), a set of trajectories has been defined which finally represents the position of the TCP inside the house frame. A cutout of the different wall has been performed and 28 working bases were defined. At each working base, taking into account the flatness via two inclinometers, a correction is applied into 727
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Fig. 10. Building Information Modeling : Yhnova building Jokic, S., Novikov, P., Maggs, S., Sadan, D., Jin, S., and Nan, C. (2014). Robotic positioning device for threedimensional printing. arXiv preprint arXiv:1406.3400. Keating, S.J., Leland, J.C., Cai, L., and Oxman, N. (2017). Toward site-specific and self-sufficient robotic fabrication on architectural scales. Science Robotics, 2(5). Khoshnevis, B. (2004). Automated construction by contour crafting related robotics and information technologies. Automation in construction, 13(1), 5–19. Labonnote, N., Rønnquist, A., Manum, B., and R¨ uther, P. (2016). Additive construction: State-of-the-art, challenges and opportunities. Automation in Construction, 72, 347–366. MX3D (2017). MX3D. http://mx3d.com/. [Online; accessed 13-november-2017]. Ronzoni, D., Olmi, R., Secchi, C., and Fantuzzi, C. (2011). Agv global localization using indistinguishable artificial landmarks. In Robotics and Automation (ICRA), 2011 IEEE International Conference on, 287–292. Tissot, C. (2010). Analyse des accidents du btp rpertoris dans epicea. http://www.inrs.fr/media.html? refINRS=ND%202322. [Online; accessed 13-november2017].
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Improvement of the mobile robot location Improvement of the mobile robot location Improvement of the mobile robot location Improvement of the mobile robot location dedicated for habitable house construction dedicated for habitable house construction Improvement of the mobile robot location dedicated for habitable house construction dedicated for by habitable house construction 3D printing 3D printing dedicated for by habitable house construction by by 3D 3D printing printing K´ evin Subrin, by Thomas S´ ebastien Garnier, 3D Bressac, printing K´ evin Subrin, Thomas Bressac, S´ ebastien Garnier,
K´ evin Subrin, ThomasElodie Bressac, S´ ebastien Garnier, Alexandre Ambiehl, Paquet, Benoit Furet K´ evin Subrin, ThomasElodie Bressac, S´ ebastien Garnier, Alexandre Ambiehl, Paquet, Benoit Furet Alexandre Ambiehl, Elodie Paquet, Benoit Furet K´ e vin Subrin, Thomas Bressac, S´ e bastien Garnier, Alexandre Ambiehl, Elodie Paquet, Benoit Furet LS2N Alexandre (Laboratory of Digital Sciences of Nantes), Nantes University, Ambiehl,Sciences Elodie of Paquet, Benoit Furet LS2N (Laboratory of Nantes University, LS2N (Laboratory Institutes of Digital DigitalofSciences of Nantes), Nantes), Nantes University, IUT (University Technology), 2 av. Prof. Jean Rouxel LS2N (Laboratory of France Digitalof Sciences of Nantes), Nantes University, IUT (University Institutes Technology), 2 Jean Rouxel IUT (University Institutes of Technology), 2 av. av. Prof. Prof. Jean Rouxel 44470 Carquefou, (e-mail: [email protected]) LS2N (Laboratory of France Digital (e-mail: Sciences of Nantes), Nantes University, IUT (University Institutes Technology), 2 av. Prof. Jean Rouxel 44470 Carquefou, [email protected]) 44470 Carquefou, France of (e-mail: [email protected]) IUT (University Institutes Technology), 2 av. Prof. Jean Rouxel 44470 Carquefou, France of (e-mail: [email protected]) 44470 building Carquefou, France (e-mail: [email protected]) Abstract: Currently, construction is beginning to consider the use of 3D printing which Abstract: Currently, building construction is consider the 3D Abstract: Currently, building construction is beginning beginning toproven consider the use use of oftechniques. 3D printing printingAwhich which can be considered as an evolution or modernization of itsto traditional new Abstract: Currently, building construction is beginning to consider the use of 3D printing can be considered as an evolution or modernization of its proven traditional techniques. A new can be considered as anapproach evolution(Foam or modernization of its proven traditional techniques. Awhich new process based on FAM Additive Manufacturing) has been patented by Nantes Abstract: Currently, building construction is beginning toproven consider thebeen use of 3D printing which can be considered as an evolution or modernization of its traditional techniques. A new process based on FAM approach (Foam Additive Manufacturing) has patented by Nantes process based onwall FAMmanufacturing approach (Foam Additive Manufacturing) haspolyurethane been patentedfoam by Nantes University. The is based on the laying of two beads can be considered as an evolution(Foam or modernization of laying its proven traditional techniques. Abeads new process based onrole FAM approach Additive has been patented by Nantes University. The wall manufacturing based on the two polyurethane University. The wall manufacturing isthe based on Manufacturing) the laying ofand two polyurethane foam beads which the of framework foris concrete and insideof outside thermalfoam insulation. processplays based onrole FAM approach (Foam Additive Manufacturing) has been patented by Nantes University. The wall manufacturing is based on the laying of two polyurethane foam beads which plays the of framework for the concrete and inside and outside thermal insulation. which plays the of framework for the concrete and architecture inside and outside thermal insulation. To perform the role laying, the development of aonrobotic integrates an foam automated University. The wall manufacturing based the laying ofand twooutside polyurethane beads which plays the role of framework foristhe concrete and inside thermal insulation. To the laying, the of architecture integrates an To perform perform theand laying, the development development of aa robotic robotic architecture integrates an isautomated automated guided vehicle an industrial robot located on it. The printing environment complex: which plays the role of framework for the concrete and inside and outside thermal insulation. To perform laying, the of robot a robotic architecture guided vehicle and an industrial robot located on it. printing environment is complex: guided vehicle and an industrial robot slab, located onhoses, it. The The printing environment isautomated complex: printed walls,the pipes inside thedevelopment concrete house form integrates complexity,an steel To perform the laying, the development of robot a robotic architecture integrates anvertical automated guided vehicle and an industrial robot located on it. The printing environment is complex: printed walls, pipes inside the concrete slab, hoses, house form complexity, vertical steel printed walls, pipes inside the concrete slab, robot hoses, house form complexity, vertical steel reinforcement. Also, the concrete slab inspection shows a flatness defect close to 25mm (regular guided vehicle and an industrial robot located onhoses, it. aThe printing environment is complex: printed walls, pipes inside the concrete slab, robot house form complexity, vertical steel reinforcement. Also, the concrete slab inspection shows flatness defect close to 25mm (regular reinforcement. Also, thethe concrete slab inspection shows a flatness defect close to 25mm (regular defect) which impacts robot accuracy. The objective is then to find the best location for printed which walls, pipes the concrete slab,The robot hoses, house form complexity, vertical steel reinforcement. Also, inside the concrete slab inspection shows a flatness defect to 25mm (regular defect) impacts the robot accuracy. objective is then to the best location for defect) which impacts the robot accuracy. The to objective isthe then to find findclose the best location for an AGV (Automated Guided Vehicle) in order perform printing in the best conditions. reinforcement. Also, the concrete slab inspection shows a flatness defect close to 25mm (regular defect) which impacts the robot accuracy. The objective is then to find the best location for an AGV (Automated Guided Vehicle) in order to perform the printing in the best conditions. an AGV (AutomatedonGuided Vehicle) in order to performfor thehouse printing in the best conditions. After a comparison current mobile robot architecture manufacturing, we present defect) impacts the robot accuracy. The objective isthe then to findinthe location for an AGV (Automated Vehicle) in order to perform printing thebest bestnavigation conditions. After aa which comparison on current mobile robot architecture for house we After comparison onGuided current mobile robot architecture for house manufacturing, we present present the location of the mobile robot in its environment where, during themanufacturing, firstinday, is an AGV (Automated Guided Vehicle) in order to perform thehouse printing the the bestnavigation conditions. After a comparison on current mobile robot architecture for manufacturing, we present the location of the mobile robot in its environment where, during the first day, the the location the improved mobile robot in its environment where, Via during first day, the navigation is is analysed andofthen to perform the house printing. the the homogeneous transformation, After a comparison on current mobile robot architecture for house manufacturing, we present the location ofthen the improved mobile robot inModel its environment where, Via during the first day, the navigation is analysed and to the house printing. the homogeneous transformation, analysed and then improved to perform perform the house printing. Via theto homogeneous transformation, we outline the Direct Geometrical and our implementation improve the accuracy of the theoutline location of Direct the improved mobile robot inModel its environment where, Via during the first day, the navigation is analysed and to perform house the homogeneous transformation, we the Geometrical and our implementation to improve accuracy of we outline thethen Direct Geometrical Model and our printing. implementation to improve the accuracy of the the robotic system. Finally, we present the the manufacturing principle and the finalthe result: a habitable analysed and then improved to perform the house printing. Via the homogeneous transformation, we outline the Direct Geometrical Model and our implementation to improve the accuracy of the robotic system. Finally, we present the manufacturing principle and the final result: a habitable roboticbysystem. Finally, we present the manufacturing principle and the final result: a habitable house 3D we outline theprinting. Direct Geometrical and our implementation to improve accuracy of the robotic Finally, we presentModel the manufacturing principle and the finalthe result: a habitable house 3D house by bysystem. 3D printing. printing. robotic system. Finally, weFederation present the manufacturing and the final a habitable house 3D (International printing. © 2018,by IFAC of Automatic Control)principle Hosting by Elsevier Ltd.result: All rights reserved. Keywords: Mobile robot, 3D printing, Accuracy improvement, Automated Guided Vehicle, house by 3D printing. Keywords: Mobile robot, Accuracy improvement, Keywords: Mobile robot, 3D 3D printing, printing, Accuracy improvement, Automated Guided Guided Vehicle, Vehicle, Foam Additive Manufacturing, Building Information ModelingAutomated Keywords: Mobile robot, 3D printing, Accuracy improvement, Automated Guided Vehicle, Foam Additive Manufacturing, Building Information Modeling Foam Additive Manufacturing, Building Information Modeling Keywords: Mobile robot, 3D printing, Accuracy improvement, Foam Additive Manufacturing, Building Information ModelingAutomated Guided Vehicle, 1. USE OF Foam ROBOTIC ARCHITECTURE FOR HOUSE otherModeling sectors. Its frequency index, representing the number Additive Manufacturing, Building Information 1. FOR sectors. Its representing the number 1. USE USE OF OF ROBOTIC ROBOTIC ARCHITECTURE FOR HOUSE HOUSE other other sectors.with Its frequency frequency index, representing the reached number 3D ARCHITECTURE PRINTING of accidents interruptindex, for 1000 employees, 1. USE OF ROBOTIC ARCHITECTURE FOR HOUSE other sectors. Its frequency index, representing the number 3D PRINTING of accidents with interrupt for 1000 employees, reached 3D PRINTING of accidents with interrupt for 1000 employees, reached 93.98 while the mean is 39.40 for all activity sectors. These 1. USE OF ROBOTIC FOR HOUSE 93.98 other sectors. Itsmean frequency index, representing the reached number 3D ARCHITECTURE PRINTING of accidents with interrupt for 1000 employees, while the is for all activity sectors. These 93.98 while the mean is 39.40 39.40 for all activity sectors. These values are quite old but it still reflects a set of expectancy. 1.1 Introduction 3D PRINTING of accidents with interrupt for 1000 reached 93.98 while the mean is 39.40 for all activity sectors. These values are quite old but it still reflects aaemployees, set of expectancy. 1.1 Introduction values are quite old but it still reflects set of expectancy. 1.1 Introduction 93.98 while the mean is 39.40 for all activity sectors. These To perform 3D construction, weof observe many values are quite oldprinting but it still reflects a set expectancy. 1.1 Introduction perform the 3D printing construction, we observe many Currently, building construction is beginning to seriously To values are quite old but it still reflects aall, set of expectancy. To perform the 3D printing construction, we observe many 1.1 Introduction aspects to reach the objectives. First of the final results Currently, construction is To perform the 3D printing construction, we observe many to reach the objectives. First of all, the final results Currently, building construction is beginning beginning to seriously consider thebuilding use of 3D printing (Labonnote et to al.seriously (2016)). aspects aspects to reach the objectives. First of all, the final results (house) have to be approved by certified organism (CSTB Currently, building construction is beginning to seriously consider the use of 3D printing (Labonnote et al. (2016)). To perform the 3D printing construction, we observe many aspects to reach the objectives. First of all, the final results (house) have to be approved by certified organism (CSTB consider the use of 3D printing (Labonnote et al. (2016)). Despite thebuilding reluctance of technical complexity (increase (house) have to Technical be approved by certified organism and Centre forofBuilding) as(CSTB far as Currently, construction is beginning to seriously consider theskills, use ofredefinition 3D printing (Labonnote et procedures) al.(increase (2016)). (Scientific Despite the reluctance of complexity aspects to reach theapproved objectives. First all,organism the final results (house) have to be by certified (CSTB (Scientific and Technical Centre for Building) as far as Despite the reluctance of technical technical complexity (increase of technical of construction (Scientific and Technical Centre for Building) as far as concerned). Before the house, a set consider the theskills, use ofredefinition 3D printing (Labonnote et procedures) al.(increase (2016)). France Despite reluctance ofthe technical complexity of of (house) is have to Technical be approved bybuilding certified organism (CSTB (Scientific and Centre for Building) as far as France is concerned). Before building the house, a set of technical technical skills, redefinition of construction construction procedures) and social (reduction of number of workers, replaceFrance Before building the house, of a the set of proveisOfconcerned). concept characterizes the Building) performance Despite the(reduction reluctance of technical complexity (increase of skills, redefinition of many construction procedures) and social of of workers, replace(Scientific and Technical Centre for as far as France isOf concerned). Before building the house, a the set prove concept characterizes the performance of andtechnical social (reduction of the the number number oftechnical workers, replace- of ment of humans by machine), solutions of prove Of concept characterizes the performance of the automated constructions systems in order the house to be, of technical skills, redefinition of construction procedures) and social (reduction of the number of workers, replacement of humans by machine), many technical solutions France is concerned). Before building the house, a set of prove Of concept characterizes the performance of the automated constructions systems in order the house to be, ment of humans by machine), many technical solutions are at increasing speed and more and morereplaceactors once automated constructions systems order system the house to be, finished, insured.characterizes Finally, the in robotic performs andgrowing social (reduction of the number oftechnical workers, ment ofconstruction humans by sector machine), many solutions are growing at speed and more and actors of prove Ofconstructions concept the performance of the automated systems in order theworking house towith be, finished, insured. Finally, the robotic system performs arethe growing at increasing increasing speed and more and more more actors once in (architects, builders, building once finished, insured. Finally, the robotic system performs the activities while being safe for people ment ofconstruction humans by sector machine), many technical solutions are growing at increasing speed and more and more actors in the (architects, builders, building automated constructions systems in order the house to be, once finished, insured. Finally, the robotic system performs activities while being safe for people working with in the construction sector (architects, builders, building the owners) are interested in these new solutions. In addition, theTo activities while being safe for people working with presentinsured. the proposed approach, wesystem review robotic arethe growing at increasing speed and solutions. morebuilders, and In more actors it. in construction sector (architects, building owners) are interested in these new addition, once finished, Finally, the robotic performs the activities while being safe for people working with it. To present the proposed approach, we review robotic owners) are interested in these newused solutions. In manufacaddition, architecture the construction sector has always additive it. To present thefor proposed approach, we review robotic used house safe 3D printing. Then, we present in the construction sector (architects, builders, building architecture owners) are interested these newused solutions. In addition, the sector has always additive manufactheTo activities while being for people working with it. present the proposed approach, we review robotic used for house 3D printing. Then, we present the construction construction sectorin has always used additive manufacturing (brick, concrete, stone, sandstone) and 3D printing architecture used for house 3D printing. Then, we present the constraints on the process and the robotic architecture. owners) are interested these newused solutions. In addition, the construction sectorin has always additive turing (brick, concrete, stone, sandstone) and 3D printing it. To present the proposed approach, we review robotic architecture used for house 3D printing. Then, we present constraints on the process and the robotic architecture. turing (brick, concrete, stone, sandstone) and 3Dmanufacprinting the of buildings is therefore only an evolution or modernization the constraints onofthethe process and the robotic architecture. complexity environment shows that finding thebuildings construction sector only has always used additive turing (brick, concrete, stone, 3Dmanufacprinting The of is an evolution modernization architecture used for house 3Dand printing. Then, we present the constraints onof the process thenot robotic architecture. The complexity the environment shows that finding buildings is therefore therefore only ansandstone) evolution or orand modernization of proven traditional techniques. The complexity of the environment shows that finding a location for the mobile robot is so easy while we turing (brick, concrete, stone, sandstone) and 3D printing is therefore only an evolution or modernization aThe of proven techniques. thelocation constraints onofthe process and isthenot robotic architecture. complexity the environment shows that finding for the mobile robot so easy while we of buildings proven traditional traditional techniques. a location for the mobile robot is not so easy while we a defect flatness on the concrete slab. Our result is therefore only evolution modernization From an economic point of an view, we areorobserving rising observe of buildings proven traditional techniques. The complexity of mobile the environment shows that finding a location for the robot is not so easy while we observe a defect flatness on the concrete slab. Our result From an economic point of view, we are observing rising observe a defect flatness on the concrete slab. Our result shows how we characterize the location of the robot and of proven traditional techniques. From an economic point of view, we are observing rising construction costs (new construction standards,...) with shows a location for the mobileonrobot is not so easy whileand we observe a defect flatness thehouse. concrete we the location of the robot From an economic point construction of view,According we are observing rising construction costs standards,...) with showswehow how we characterize characterize the location ofslab. the Our robotresult and improve it to print the construction costs (new (new construction standards,...) with how significant occupational risks. to the INRS observe a defect flatness on the concrete slab. Our result shows we characterize the house. location of the robot and how improve it From an economic point construction of view,According we are observing rising construction costs (new standards,...) with significant occupational risks. toaccounts the INRS INRS how we wehow improve it to to print print the the house. significant occupational risks. According to the (Tissot (2010)), in 2007, the building sector for how showswehow we characterize the house. location of the robot and improve it to print the construction costs (new construction standards,...) with significant occupational risks. According to the INRS (Tissot (2010)), in 2007, the building sector accounts for (Tissot in 2007, the building 8.6% of (2010)), all occupational employees in France. This sectortoaccounts for how we improve it to print the house. significant risks. According the INRS (Tissot in with 2007, the building sector accounts 8.6% all employees in France. This 8.6% of ofof(2010)), all employees ininterrupt, France. This sector accounts for for 18.2% accidents 20.7% of accidents (Tissot (2010)), in with 2007, the building sector accountswith for 8.6% of all employees in France. This 18.2% of accidents interrupt, 20.7% of accidents with 18.2% of accidents with interrupt, 20.7% of accidents with permanent disability and 29.6% of deaths compared to 8.6% ofofall employees ininterrupt, France. This sector accountswith for 18.2% accidents with 20.7% of accidents permanent disability and 29.6% of deaths compared permanent disability and 29.6% of deaths compared to to 18.2% of accidents with interrupt, 20.7% of accidents with permanent disability and 29.6% of deaths compared to Copyright © 2018, 2018 IFAC permanent disability and 29.6%Federation of deaths compared to723Hosting by Elsevier Ltd. All rights reserved. 2405-8963 © IFAC (International of Automatic Control) Copyright © 2018 IFAC 723 Copyright 2018 responsibility IFAC 723Control. Peer review©under of International Federation of Automatic Copyright © 2018 IFAC 723 10.1016/j.ifacol.2018.08.403 Copyright © 2018 IFAC 723
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Fig. 1. Contourcrafting(a), Winsun(b), FastBrick Construction(c), Construction 3D(d), MX3D(e), MIT robot(f) 1.2 State of the art
Today, companies and research laboratories search future market aiming at building construction via automated processes (Fig. 1). The architectures used for the laying of material are generally cartesian (Contourcrafting (Khoshnevis (2004)) where we observe a rail on which a structure and a crossbar allow the 3D printing (Fig. 1a). In the same way, Winsun3d (Winsun (2015)) proposes an architecture where the structure can be tilted (Fig. 1b). Other approaches focus on a mobile robot with telescopic arm in order to lay out bricks such as Fastbrick Robotic Construction (FastBrickConstruction (2016))(Fig. 1c) to lay out foam such as MIT solution (Keating et al. (2017))(Fig. 1f) or to lay out concrete (Construction3D (2017))(Fig. 1d). These architectures are heavy with several tons of equipment. Other approaches are currently being conducted via industrial robots using a print head for the deposit of fusion wire (Jokic et al. (2014))(Fig. 1e) or by welding processes such as the addition of metal by fusion (MX3D (2017)). The latter approach, led by the firm MX3D became known by the manufacture of a bridge using two robots that move on what they have built. All of these architectures denote the high activity on this topic. The construction time is decreased via a better management of the manufacturing process. In addition, the tough activity is partly devolved to the robotic means; thus, the difficulty of the activity is greatly reduced. In addition, with the digitalization of the activity, it is then possible to improve the construction flow of buildings. However, the emergence of these new means puts forward difficulties concerning the implementation of these processes on site and the investment of the means of printing with the associated training. The implementation of these new processes aims to redesign the principles of construction. Principles, morphologies, kinematics of the robotic system, processes (material,...) allow to redefine the know-how : new architectural design can be envisioned. 724
Fig. 2. Innoprint3D project where a shelter has been built 2. 3D PRINTING WITH A MOBILE ROBOT In the next section, we present the Foam Additive Manufacturing and the manufacturing process which has been used to manufacture the habitable house. 2.1 Foam Additive Manufacturing and constraints on the process FAM or Foam Additive Manufacturing technology is a marriage between additive foam manufacturing and topological optimization for 3D printing of large parts. In order to develop additive manufacturing skills for large dimensions, the University of Nantes has led various developments that have been materialized by a demonstrator called INNOPRINT3D. The robotic 3D printing of a shelter made of polyurethane foam (1.75mx1.75mx2.5m) is built up in 30min only. An industrial robot deposits foam which in contact with the air is expanded from 30 to 45 times its volume. The main challenge concerns the trajectory management with the expansion of the foam to print the unsupported roof. After analyzing these first results and summarizing previous work, several patents which protect the intellectual properties of the solution have been submitted (figure 3). This building principle makes it possible to quickly print all types of construction walls with flat or even complex geometries. Regarding existing self-supported insulated
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formwork elements which are commercially available, this new process gives a freedom in shape. Moreover, it combines several trades such as masons and insulation. This work named Batiprint3D project has been supported by the University of Nantes, the SATT Ouest Valorisation and several companies. It focuses on the realization of a ”social housing”. Then, as a second step, we developed a 3D printing solution for single-family buildings by creating an exploitable means directly on site. To do this, we have decomposed our development into three areas of research: process (developed in this paper), formulation (Concrete and foam properties) and characterization (materials behaviors of the house).
well manage the Tool Center Point of the industrial robot in its environment.
Fig. 5. Yhnova concrete slab floor flatness defect in mm 2.2 Architecture of the mobile robot
Fig. 3. Patent where the concrete is deposited between two layers of foam that serve as framework The main issue is the combination of a tool (mobile and articulated robot) with a material (Polyurethane and concrete) allowing the realization in situ of the wall. To do this, the tool must be transportable, adapted to the external environmental constraints of the construction site and stable to allow injection of the material without significant performance tolerance. From the digital model of the house performed by an architect, the house edge is cut to generate 28 areas where the robot accessibility enables us to print. Once the slab is ready (figure 4), our robotic solution prints it on the building site (structure and insulation), and once the elevation of the walls is completed, the mobile robot emerges through an opening. The house which has been printed is 95m2 . The walls are 4m high.
The mobile robot includes an Automated Guided Vehicle (AGV) and an industrial robot. The Automated Guided Vehicle is a BA Systems robot with safety laser scanners. This robotic system, following the odometry it uses, offers good performances in terms of accuracy inside large space (10mm) (Vasiljevi´c et al. (2016), Ronzoni et al. (2011)). A set of reflectors is positioned around the concrete slab floor to manage the location of the AGV (figure 6). A lifter allows to raise the Staubli Industrial robot. On the platform, the robot controller and a set of counterweight allow to use the mobile robot in a safe manner. 3. MODELING AND IDENTIFICATION OF THE MOBILE ROBOT The location improvement is based on the management of the mobile robot. A set of constraints (printed walls, pipes inside the concrete slab, robot hoses, house form complexity, vertical steel reinforcement, floor horizontality) are taken into account during the first layers. We present the notation we use to implement a correction matrix taking into account the inclination of the AGV. Corrections matrixes allow to define the position of the Tool Center Point
Fig. 4. Yhnova concrete slab floor With a laser tracker whose measurement accuracy is below 0.01mm, the flatness of the floor has been measured: it exists a flatness defect of 25.2mm (figure 5) which is inside the tolerance we can expect from such a floor. In this way, the mobile robot is equipped with two inclinometers to 725
Fig. 6. Laser scanner and the reflectors for the robot navigation
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AHouseT CP = AHouseAGV ∗ AAGV P sinav ∗ AP sinavLif ter ∗ ALif terRobot ∗ ARobotW rist ∗ AW ristT CP (1) This equation is theoretical and it must be included a correction due to the flatness of the floor. The AGV location given by the AGV software considers the position of the Psinav inside Ohouse Xhouse Yhouse Zhouse which is the point A located at 4m high. To take into account the flatness, two inclinometers have been installed following Zpsinav to detect the rotation of the mobile robot around XAgv and YAgv . The correction is a homogenous matrix which integrates the values of P itch and Roll. Taking into account the flatness, the description of the point inside the robot frame Drobot Xrobot Yrobot Zrobot is Fig. 7. Robot frames
−1 x ARobotT CP = A−1 Lif terRobot ∗ AP sinavLif ter ∗ R (P itch)
(TCP). In our case, we independently manage the AGV and the industrial robot. All the corrections are implemented inside the programming of the industrial robot. Next, we present a set of results to highlight the research of the best location to print the walls.
−1 ∗ Ry (Roll) ∗ A−1 AGV P sinav ∗ AHouseAGV
(2)
3.3 Toward the improvement of the location of the AGV We present here the different issues which permit the location improvement of the AGV.
3.1 Notation Homogeneous transformation are introduced where Aij represents the position and the orientation of a coordinate system j (Oj xj yj zj ) regarding to a coordinate system i (Oi xi yi zi ) (Dombre and Khalil (2002)). 3.2 Modeling of the mobile robot The direct geometrical model allows to define the positing of the TCP following the joint position. This architecture is kinematically redundant with 4 Degrees of Freedom (DoFs) as far the AGV is concerned (θpsi , Xpsi , Ypsi , Zpsi ) and with 6 DoFs (q1 ,...,q6 ) as far the industrial robot is concerned. Two systems are considered and their management is independent. The path that the robot must follow is defined in the frame Ohouse Xhouse Yhouse Zhouse . To print the wall, the AGV stays fixed inside Ohouse Xhouse Yhouse Zhouse . We consider first the position of the frame Drobot Xrobot Yrobot Zrobot which takes into account the flatness of the floor. Then, we consider the position of the TCP inside the robot frame. The AGV location is defined inside the house frame. The Psinav (safety laser scanner for the location) scans a set of reflectors around the house. This scan permits the definition of a virtual point FAGV . The definition by the AGV controller of the location does not take into account the flatness of the floor. We fixed 2 inclinometers to determine the pitch and roll of the Automated Guided Vehicle. The location returned by the AGV software is the frame BAgv XAgv YAgv ZAgv . Following the way to define it, it does not consider the flatness defect. A rigid transformation is so considered (Equation 1).
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Printed wall detection In order to print the wall, 28 working bases were defined to print house walls. Each working base is located inside two vertical reinforcement. Their location is not so easy to define due to the scanner located at the basis of the AGV. This type of AGV focuses more its activity on the carrying of loadings inside warehouse. This scanner permits the navigation and it stops the AGV when an obstacle is detected. In our case, it detects the printed wall and we were not able to be too close to the printed wall. Robot Hoses In order to be able to print, various hoses are fixed to the end effector. Cable carriers allow to manage the travel of the lifter. Then, a set of electric and hydraulic wires permits the printing. The position of this hoses is important to be able to use the robot in a large workspace. House form complexity In order to print large foam bead, the printing takes place on the side of the AGV. The dimensions of the AGV (1.6m length * 1m wide) are quite important and to be able to print the extremity of the house (working base 5 to 7 and 24 on figure 8), robot hoses, dummies (wood structure which represents windows, doors), AGV turning radius and safety laser scanner detection complexifies the research of a good location. Vertical steel reinforcement To respect building norm, vertical steel reinforcement was inserted inside the wall. Each one was hand-positioned. We played a set of trajectories without printing to ensure the collision avoidance. Floor flatness This aspect is taken into account with the two inclinometers. We present in the following section the accuracy improvement with this instrumentation denoting its importance.
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Fig. 9. Location error at 4m high due to angling between two working bases the industrial robot programm to ensure the continuity of the trajectory between two working bases. The house was printed in 54 hours (33 hours theoretically of 3D printing) during september 2017. The thermal properties highlights that such a construction replies to RT 2012 french norm and is 30% better as expected.
Fig. 8. AGV Location during the first day to simulate the printing (a) and AGV location during the printing (b) Labels are in mm Location improvement During all the printing, the AGV location was registered (Figure 8). Label X and label Y represent the cartesian position of the AGV in mm. 28 wall sections depending on their length, geometry (curves, corners) define 28 working bases. We highlight 3 areas named Z1, Z2 and Z3. Z1 area is really interesting due to the fact that we observed a significant defect of flatness here (figure 5). In order to ensure the printing quality, we analyze the difference of angling between two working bases. Figure 9 presents the location error induced by the angling difference between two working bases and show that without inclinometers, at 4m high, we would have an offset of 60mm between the two printing areas. This result shows the accuracy improvement of the mobile robot. Z2 area had a different problematic due to the presence of a common wall. The location of the AGV was important to be able to print as close as possible to the wall. Finally, Z3 presents another complexity of the architecture: a short wall between two vertical steel reinforcement due to the presence of the main door. Various tests allow to define the best AGV location to print the wall. 4. CONCLUSION AND PERSPECTIVES
In this paper, we presented the house building with a new and patented process based on Foam Additive Manufacturing. The integration of such a complex system has an impact on the AGV location and following the flatness of the concrete slab in the higher position of the lifter, an offset up to 60mm must be corrected. To solve the issue, a correction matrix has been implemented to relocate the industrial robot while ensuring the feasibility of the trajectory. The house building is a first step to highlight the potential of such a process (Figure 10). As a perspective, it will be convenient to study the dynamical behavior in order to improve the process speed. As a prototype, the laying dynamic was smooth. It is important, regarding the activity sector, to reach a reliable and efficient solution. 5. ACKNOWLEDGEMENT We acknowledge Nicolas Houssais. We acknowledge Philippe Poulain from GeM laboratory at IUT Saint-Nazaire We acknowledge the support of the following companies : BA Systems, Bouygues Batiment, LafargeHolcim, CSTB, CNRS, Nantes University, SATT Ouest Valorisation, Caisse des d´epots, Nantes M´etropole, Nantes m´etropole Habitat. More details on the house building is available on the website http://www.batiprint3d.fr/ REFERENCES
As a result, we present the different phases which led to the house building. First of all, based on the BIM (numerical definition of the house to be printed), a set of trajectories has been defined which finally represents the position of the TCP inside the house frame. A cutout of the different wall has been performed and 28 working bases were defined. At each working base, taking into account the flatness via two inclinometers, a correction is applied into 727
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