The work performed from the beginning of the project has focussed on obtaining a fully functional production cell with end user validated manufacturing capability. The end of RP1 thus marks a transition phase into the TRL8-stage of the project.
In the first reporting period from 01/03/2020 to 28/02/2021, we have achieved the following results:
1. Preparation and assembly of a containerized work platform for housing the industrial robot and an automated tool changing system.
2. Development, integration and testing of a proprietary wire cutting tool
3. System design, integration and testing of a coating system
4. Development, integration and testing of a sanding tool for surface refinement
5. Development and preparation of a milling tool for edge finishing
6. Adaptation and augmentation of the Cloud-based software solution to translate the parametric formwork design input into robotic movement output through the Sculptor® robot control architecture.
7. A graphical user interface (GUI) design
8. System tests and production of formwork with different levels of detailing and end user defined typology constraints
The containerized platform consists of two standard open-sided 20-foot containers. One container houses the industrial manipulator and the associated hardware while the other container is placed parallel to the housing container and functions as a workstation on which to place the work object (i.e. EPS blocks). In this configuration, the system can perform all operations in an automated fashion – i.e. cut the EPS in a sweeping motion, apply a surface treatment, refine the surface, and perform edge-finishing for perfect encasement – based on inputs and prompts from a superintendent via a simple tablet interface.
The work envelope is designed to accommodate the majority of staircases produced by pre-manufacturers. With the motion constraints of the robot and the width of the wire tool, tests have validated that staircase designs of > 4,2 x 1,2 metres can be produced.
Surface quality is paramount to pre-manufacturers since staircases provide use surfaces. For this reason, much testing has been done to develop a custom coating solution with an surface with good release properties and good durability. As of RP1, a coating solution has been implemented and tested with a non-toxic, water-based self-crosslinking material. Since surface treatment is so essential, we have implemented the system in an open-ended way such that adjustments can be made to both application and material composition based on more extensive use case data and end user feedback during RP2.
To achieve perfect levelness, a sanding tool has been implemented and a milling tool which extends the height of the formwork has been designed to ensure perfect evenness of the sides for perfect encasement.
As of RP1, a beta version of the SmartStair production cell has been built and its primary functionality validated.
