Engineering topics

Hayes, Nolan [ORNL] (ORCID:0000000332245718)

Publications and source records attributed to Hayes, Nolan [ORNL] (ORCID:0000000332245718).

7 records

DOE OSTI2026

Automated tape-target centering based on template matching for construction measurement tasks using robotic total station

Robotic total stations have transformed surveying and construction mapping through precise, efficient, and automated measurements. These instruments integrate a theodolite, which measures horizontal and vertical angles, with an electronic distance measurement (EDM) unit to determine distances, allowing accurate 3D measurement of observable points. Traditionally, users manually aimed the total station at a target. Recent advancements in robotic motor control and integration of cameras now enable automatic rotation and aiming, typically requiring only a single operator to position the target. Automated aiming is commonly performed using retroreflector prisms, which reflect light back to the source with minimal scattering, enabling high-precision measurements over long distances. However, retroreflectors, especially those designed for 360 degree, can be expensive and impractical for certain applications. This paper presents an algorithm for automating the center detection of low-cost disposable tape targets using the total station's onboard camera and a template matching algorithm. The algorithm identifies the target's center pixel in the image, and the instrument is commanded to aim at that location. We evaluated the performance of this template-matching-based centering method under various distances, angles, lighting conditions, and field environments, comparing its results to both manual aiming and conventional automated aiming of tape targets. Manual aiming was used as the baseline operational reference in the absence of an independent ground-truth measurement. The proposed approach achieves target centering results comparable to the manual baseline. This method provides a cost-effective alternative for high-precision applications where retroreflector targets are constrained by budget or logistics.

Harrington, Joshua [ORNL]↗

DOE OSTI2025

Dynamic Analysis of a Six-Cable Parallel Robot for Automated Panelized Building Retrofits

Cable-Driven Parallel Robots (CDPRs) are highly suitable for automated panelized building retrofits, thanks to their compact footprint and high payload-to-weight ratio. A common CDPR configuration featuring eight cables, where the anchors form a rectangular prism in front of the building facade, offers a large wrench feasible workspace and good control versatility. However, installing upper anchor points requires additional support structures, such as towers or beams, increasing setup complexity and posing logistical challenges in construction settings. To mitigate these challenges, we propose a six-cable CDPR model specifically designed for automated panelized building retrofits. Although the feasible workspace is limited, our analysis shows that the proposed CDPR adequately covers the critical areas required for panel installation. To validate that the six-cable system can effectively transport the end effector to the desired installation pose, we calculated optimal trajectories based on a constrained dynamic model. The simulation results of the six-cable CDPR demonstrate promising potential for automated panelized building retrofits, effectively balancing simplicity, cost-effectiveness, and functionality.

Liu, Yifang [ORNL] (ORCID:0000000190817417)↗

DOE OSTI2025

Integration of a real-time orientation measurement system for a real-time evaluator (RTE) to measure the position and orientation of crane-lifted components

Prefabrication of building components holds the potential to revolutionize the construction industry. Prefabrication consists of manufacturing building components, modules, and other elements in a factory to be shipped and installed on a construction site. Prefabricated components have been produced for various applications including precast concrete panels for new construction and exterior wall retrofits. The manufacturing process has seen much innovation in recent years; however, the installation process has seen minimal advancements. A real-time evaluator (RTE) was developed to reduce the installation cost of prefabricated components by reducing installation time, decreasing rework, and improving accuracy. The RTE uses off-the-shelf hardware and novel algorithms to assist erectors with component installation by measuring the real-time positions of connections and prefabricated components, providing installation guidance through a graphical user interface, and monitoring the accumulated installation errors. An overview of the RTE and the proposed workflow is presented. Previous on-site demonstrations provided valuable feedback from users on the potential areas for improvement of the system. One common request was real-time measurement of component orientation during lifting, a process that previously required that the component remain stationary while the laser tracker cycled through target prisms. This paper will present the incorporation and testing of a real-time orientation measurement system as it was implemented into the RTE, allowing for measurement of component orientation during movement.

Selvakumar, Balaji [ORNL]↗

DOE OSTI2025

Automated segmentation and analysis of point clouds of pier foundations using Pier Inspection and Evaluation Report (PIER)

Pier foundations are commonly used in locations with unstable soil or where other types of foundations are unsuitable or cost prohibitive. A pier foundation consists of vertical columns to support the structure and elevate it above the ground. Common materials for pier foundations include masonry, concrete, timber, and steel. The methods for accurate placement of pier foundations have remained relatively unchanged for decades. For simple installations, construction chalk lines are used to layout the locations of piers to ensure accurate placement and elevation. For more complex installations, surveying instruments operated by trained professionals are employed to accurately locate piers and assess correct elevation before construction. After installation, another survey may need to be performed to assess the quality of the as-built foundation. However, with the advent of terrestrial laser scanners (TLS), the means now exist for contractors to conduct their own assessments of as-built foundations. The major barrier preventing contractors from performing their own assessments of as-built foundation quality is the segmentation and analysis of point cloud data, a skill that often requires a trained user. The objective of this research is to develop a software tool (PIER: Pier Inspection and Evaluation Report) to enable automated segmentation and analysis of point clouds of pier foundations. In this paper, the automated segmentation and analysis algorithms are detailed. A mockup lay out of pier foundations was built using concrete masonry units, and the algorithms were tested to evaluate performance. Limitations of the current algorithms and future research direction are discussed.

Turki, Amine [ORNL]↗

DOE OSTI2025

P2P: Point Cloud to Panel Layout Optimization

Building envelope retrofits, despite their benefits on enhancing energy efficiency, progress slowly due to high operating costs. Overclad panelized systems present an attractive solution to make retrofits affordable and easy to install. However, several stages of the retrofit process remain disconnected, suboptimal, and require significant human intervention. This study aims to bridge the gap between digital twin generation and overclad panel installation by automating the design of an optimal panel layout directly from a building envelope point cloud. In this end-to-end approach, the dimensional twin is generated by segmenting the facade point cloud. The facade then undergoes a three-step process to generate an optimized panel layout for integration with automated placement systems.

Philips, Nisha Deborah [ORNL]↗

DOE OSTI2025

Deep Point Cloud Building Envelope Segmentation (DeeP-CuBES) using Deep Learning

Building Information Modeling (BIM) plays an important role in building design and construction, particularly for achieving energy-efficient retrofits. Building envelope retrofits using panelized prefabricated system, such as those popularized by the Energiesprong program, need accurate as-built dimensions of facade features (windows, doors, etc.) to achieve the desired thermal and air tightness. Traditionally, building surveying is done manually, resulting in a time-consuming and labor-intensive process. Recently, 3D point clouds from terrestrial LiDAR have been used to automate the generation of as-built dimensions of existing buildings. However, automated BIM using LiDAR relies on solving the point cloud semantic segmentation (PCSS) problem. In this work, we propose a robust pipeline for solving the PCSS problem using deep neural networks, focusing on overcoming challenges posed by imbalanced datasets and complex architectural features. We introduce the first high-density, labeled, and validated building envelope point cloud dataset derived from multiple building scans, specifically curated to tackle challenges in facade-level segmentation. Results from the trained neural networks show that advanced attention-based architectures and incorporating radiometry (light intensity and RGB) features significantly boost segmentation accuracy for windows and doors.

Selvakumar, Balaji [ORNL]↗

DOE OSTI2025

A review of prefabricated overclad panels for building energy retrofits

Over 50% of existing buildings in the US were constructed before 1980 and lack modern, energy-efficient technologies. Despite the large number of old buildings, less than 2% of buildings are retrofitted each year with many of those retrofits consisting of small incremental improvements that often ignore the building envelope. The opaque building envelope affects 25% of building energy use equating to 10% of total US primary energy use. To meet decarbonization goals by 2035, the US must increase the rate of retrofit of existing building envelopes. The process of prefabrication is one potential opportunity to increase the rate of envelope retrofits and reduce costs. Prefabrication is the process of manufacturing construction components in a controlled environment before shipping them on-site to perform assembly of the construction. The process of prefabrication has been demonstrated to increase production efficiency, quality control, and rate of production. Prefabricated overclad panels, consisting of a cladding material and insulation designed to be installed over the existing envelope, have been successfully used to retrofit existing buildings in countries other than the US; however, the technology still has some barriers to major market adoption within the US. This paper will present a review of current implementations and demonstrations of prefabricated overclad panels. The review will include identification of panel types, materials, and applications and aims to identify barriers to retrofit market entry and widespread adoption.

Hayes, Nolan [ORNL] (ORCID:0000000332245718)↗