Autonomous fabrication of mechatronic systems

Patent metadata

Field	Value
Publication number	US-12594725-B2
Application number	US-202318298116-A
Country	US
Kind code	B2
Filing date	Apr 10, 2023
Priority date	Jun 10, 2022
Publication date	Apr 7, 2026
Grant date	Apr 7, 2026

Abstract

An autonomous fabrication method and system are described. A multi-axis robotic arm having at least one end effector is provided, where the at least one end effector comprises an additive manufacturing (AM) toolhead and a component gripping mechanism. The multi-axis robotic arm is directed to fabricate a first portion of an object in a workspace using the AM toolhead, select a prefabricated part using the component gripping mechanism, place the prefabricated part in a predetermined location of the object, and fabricate a second portion of the object in the workspace using the AM toolhead. The object may be one of an unmanned aerial vehicle and an unmanned ground-based vehicle.

First claim

Therefore, the following is claimed:

1 . An autonomous fabrication method, comprising:
providing a multi-axis robotic arm having at least one end effector, wherein the at least one end effector comprises an additive manufacturing (AM) toolhead and a component gripping mechanism; directing, by processing circuitry, the multi-axis robotic arm, to select a prefabricated part using the component gripping mechanism and placing, by the multi-axis robotic arm, the prefabricated part in a predetermined location of an object, wherein the object is an unmanned aerial vehicle, an unmanned ground-based vehicle, or an unmanned water-based vehicle; and fabricating, by the multi-axis robotic arm, a portion of the object in a workspace using the AM toolhead.

2 . The autonomous fabrication method according to claim 1 , wherein:
the prefabricated part is a plurality of prefabricated parts having a common set of design features, at least two of the plurality of prefabricated parts selected from a group consisting of: a battery; a microcontroller; an imaging device; a motor; a propeller; a wheel; a global positioning system (GPS) module; and a networking module; and the autonomous fabrication method further comprises, after completion of fabrication of the object, instructing the object to navigate a predetermined path directly from the workspace.

3 . The autonomous fabrication method according to claim 2 , further comprising directing, by the processing circuitry, an actuator to apply force laterally to the object as fabricated prior to instructing the object to navigate the predetermined path.

4 . The autonomous fabrication method according to claim 1 , wherein:
the portion of the object is a second portion of the object fabricated after placement of the prefabricated part; the method further comprises, prior to placement of the prefabricated part, fabricating, by the multi-axis robotic arm, a first portion of the object in the workspace using the AM toolhead; and the prefabricated part as selected is one of a plurality of prefabricated parts having a common set of design features positioned separate from and proximate to the workspace.

5 . The autonomous fabrication method according to claim 1 , wherein:
the at least one end effector is a single end effector having the AM toolhead and the component gripping mechanism, the AM toolhead and the component gripping mechanism being positioned orthogonal to one another; and the autonomous fabrication method further comprises directing, by a controller of the processing circuitry, the multi-axis robotic arm to transition between the AM toolhead and the component gripping mechanism through a rotation of the single end effector.

6 . The autonomous fabrication method according to claim 1 , wherein:
the prefabricated part as placed is a first electronic device; the autonomous fabrication method further comprises selecting, by the multi-axis robotic arm, a second electronic device using the component gripping mechanism; forming, by the multi-axis robotic arm, a wired connection between the first electronic device and the second electronic device; and placing, by the multi-axis robotic arm, the second electronic device in the predetermined location of the object such that the wired connection is maintained.

7 . The autonomous fabrication method according to claim 6 , wherein the forming, by the multi-axis robotic arm, the wired connection between the first electronic device and the second electronic device further comprises:
orienting, by the multi-axis robotic arm, the second electronic device positioned proximate to a first connector of the first electronic device, the second electronic device comprising a second connector, the first connector being coupled to a wire; positioning, by the multi-axis robotic arm, a second prefabricated part proximate to the first connector of the first electronic device such that the first connector and the second connector are coupled to one another through the wire; and repositioning, by the multi-axis robotic arm, the second electronic device in the predetermined location of the object such that the wired connection is maintained.

8 . The autonomous fabrication method according to claim 1 , further comprising:
providing a host client, a first controller of the processing circuitry configured to control the multi-axis robotic arm, a second controller of the processing circuitry configured to control an actuator configured to apply lateral force to the object as fabricated, and a third controller of the processing circuitry configured to control the AM toolhead and the component gripping mechanism of the end effector; and subscribing, by the first controller of the processing circuitry, the second controller of the processing circuitry, and the third controller of the processing circuitry, with the host client through an instruction messaging service, wherein corresponding instructions accessed by the host client are pulled from the instruction messaging service by the first controller of the processing circuitry, the second controller of the processing circuitry, and the third controller of the processing circuitry.

9 . The autonomous fabrication method according to claim 1 , wherein the multi-axis robotic arm has six degrees-of-freedom (6-DoF).

10 . An autonomous fabrication system, comprising:
a multi-axis robotic arm having at least one end effector, wherein the at least one end effector comprises an additive manufacturing (AM) toolhead and a component gripping mechanism; and processing circuitry configured to:
direct the multi-axis robotic arm to select a prefabricated part using the component gripping mechanism and place the prefabricated part in a predetermined location of an object, wherein the object is an unmanned aerial vehicle, an unmanned ground-based vehicle, or an unmanned water-based vehicle; and
direct the multi-axis robotic arm to fabricate a portion of the object in a workspace using the AM toolhead.

11 . The autonomous fabrication system according to claim 10 , wherein:
the prefabricated part is a plurality of prefabricated parts having a common set of design features, at least two of the plurality of prefabricated parts selected from a group consisting of: a battery; a microcontroller; an imaging device; a motor; a propeller; a wheel; a global positioning system (GPS) module; and a networking module; and the processing circuitry is further configured to, after completion of fabrication of the object, instruct the object to navigate a predetermined path directly from the workspace.

12 . The autonomous fabrication system according to claim 11 , wherein the processing circuitry is further configured to engage an actuator to apply force laterally to the object as fabricated prior to the object navigating the predetermined path.

13 . The autonomous fabrication system according to claim 10 , wherein:
the portion of the object is a second portion of the object fabricated after placement of the prefabricated part; the processing circuitry is further configured to, prior to placement of the prefabricated part on the object, direct the multi-axis robotic arm to fabricate a first portion of the object in the workspace using the AM toolhead; and the prefabricated part as selected is one of a plurality of prefabricated parts having a common set of design features positioned separate from and proximate to the workspace.

14 . The autonomous fabrication system according to claim 10 , wherein:
the at least one end effector is a single end effector having the AM toolhead and the component gripping mechanism, the AM t

Assignees

• Virginia Tech Intellectual Properties Inc

Inventors

• Kosmal Tadeusz
• Beaumont Kieran
• Link Eric
• Phillips Dalton
• Pulling Conner
• Lowe James
• Williams Christopher
• Kubalak Joseph

Classifications

• B25J9/1664

  characterised by motion, path, trajectory planning · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B25J9/1687

  Assembly, peg and hole, palletising, straight line, weaving pattern movement · CPC title