Automated insulation application system and method

An automated drywalling system comprising:

• a base unit;
• an elongated robotic arm that extends between a base end and a distal end, the robotic arm coupled to the base unit at the base end of the robotic arm;
• an insulation end effector coupled at the distal end of the robotic arm, the insulation end effector configured to apply insulation material to a target surface;
• one or more vision systems;
• and
• a computing device executing a computational planner that:
• obtains target surface data from the one or more vision systems, the target surface data including information regarding a configuration of wall assembly including a plurality of studs;
• automatically generates instructions for driving the insulation end effector, robotic arm, and base unit to perform at least one insulation application task that includes applying insulation material, via the insulation end effector, to a target surface between the respective studs of the wall assembly, the generating based at least in part on the target surface data;
• automatically drives the end effector, robotic arm, and base unit to perform the at least one insulation application task;
• obtains insulation material application data from the one or more vision systems, the insulation material application data including a current insulation application profile of insulation material being applied to the wall assembly;
• automatically updates the instructions for driving at least one of the insulation end effector, robotic arm, and base unit to perform at least one updated insulation application task based at least in part on determining that the current insulation application profile does not match a desired insulation profile, the updated instructions including updated application of the insulation material to the target surface to generate an updated insulation application profile that matches the desired insulation profile;
• and
• automatically drives, the at least one of the insulation end effector, robotic arm, and base unit to perform the at least one updated insulation application task to apply the insulation material to the target surface with the updated insulation application profile that matches the desired insulation profile.

An automated insulation application system comprising:

• a base unit that includes:
• an insulation material source configured to store insulation material;
• and
• a platform;
• a positioning stage that extends between a base end and a distal end, the positioning stage coupled to the base unit on the platform at the base end of the positioning stage;
• an insulation end effector coupled at the distal end of the positioning stage, the insulation end effector including a spray gun configured to generate a spray of insulation material from a nozzle of the spray gun, the spray gun coupled with a insulation material tube extending from the insulation material source via the positioning stage, the spray gun configured to receive insulation material from the insulation material source via the insulation material tube to generate the spray of insulation material;
• one or more vision systems;
• one or more sensors;
• a computing device executing a computational planner that:
• automatically generates instructions for driving the insulation end effector and positioning stage to perform at least one insulation application task that includes applying insulation material via the insulation end effector to a target surface between exposed studs of an open and incomplete wall assembly, the generating based at least in part on obtained target surface data;
• drives the end effector and positioning stage to perform the at least one insulation application task to specifically apply insulation material to the target surface between the exposed studs of the incomplete wall assembly;
• obtains insulation material application data from the one or more vision systems or the one or more sensors, the insulation material application data including a current insulation application profile of insulation material being applied to a target surface;
• updates instructions for driving at least one of the insulation end effector and positioning stage to perform at least one updated insulation application task based at least in part on determining that the current insulation application profile does not match a desired insulation profile, the updated instructions including updated application of the insulation material to the target surface to generate an updated insulation application profile that matches the desired insulation profile;
• and
• drives, the at least one of the insulation end effector and positioning stage to perform the at least one updated insulation application task to apply the insulation material to the target surface with the updated insulation application profile that matches the desired insulation profile.