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At least 19 records

Cable-Driven Parallel Robot (CDPR) for Panelized Envelope Retrofits: Feasible Workspace Analysis

Recent decades have seen remarkable progress in the field of robotic-assisted construction. Cable-driven parallel robots (CDPRs) emerge as promising tools for automating construction processes, due to their advantageous features such as scalability, reconfigurability, compact design, and high payload-to-weight ratio. This paper uses a simple static model to determine the feasibility of a CDPR for overclad panel installation in building envelope retrofits. Given that the building facade needs to be a subset of the CDPR’s wrench-feasible workspace, we focus on the sensitivity of the workspace concerning various cable arrangements and CDPR frame sizes (e.g., height and width extensions). Our analysis indicates that no cable arrangement satisfies the requirement of complete facade coverage and avoids cable-to-panel collisions. Thus, frame extension is needed to enhance coverage. However, in densely populated areas where width extension is limited by space constraints, height extension alone is insufficient to guarantee full facade coverage. This paper pioneers the investigation of CDPRs for panelized envelope retrofits, showcasing their advantages and limitations and paving the way for further research and development.

Liu, Yifang↗

Component pose reconstruction using a single robotic total station for panelized building envelopes

The construction industry can benefit greatly from increased automation in construction processes in terms of precision, time, and labor costs. This is especially true for prefabricated construction for either new buildings or envelope retrofits. Here, prefabricated components are manufactured offsite according to design specifications and installed onsite. Accurate information on the component’s position and orientation (pose) is needed to achieve this. A tool named “Real-Time Evaluator” (RTE), designed to autonomously track prefabricated components as they are being installed and provide real-time installation instructions, is currently under development using a single robotic total station. This is challenging since at least three points are needed to determine the pose of an object in space. To achieve this goal with a single robotic total station, two key algorithms were developed: the “resection” algorithm aligns the digital twin with the physical twin regardless of the location of the total station, and the “transformation” algorithm gives instructions of translations and rotations to installers to achieve the desired installation pose. The algorithms were evaluated experimentally on a lab-scale demonstration. Results show that the resection algorithm achieved an average error of < 3.1 mm, while the transformation algorithm predicted the rotation angle along a single axis with an error of < 0.5◦.

Tang, Mengjia↗

Thermally Anisotropic Building Envelope Integration into Panelized Metal Construction: Laboratory Evaluation in Guarded Hot Box

The Thermally Anisotropic Building Envelope (TABE) is an active building envelope system that can exchange thermal energy with a storage medium to reduce the building’s energy demand. TABE redirects thermal energy along thin conductive layers in the building envelope to hydronic loops that are connected to thermal energy storage (TES), where it will be available to offset future energy demand when the conditions are favorable. TABEs can also be connected with a geothermal loop to reduce the building’s heating and cooling loads. Due to the importance of thermally conductive metal layers to TABE function, this technology has potential for easy adoption into panelized metal construction. In this study, we illustrate the construction process of prototype metal panels containing TABE and the laboratory evaluation in Oak Ridge National Laboratory’s rotatable guarded hot box. The thermal performance of the prototype panel was assessed for both baseline and operational cases and the total heat flow extracted from the panel by TABE was quantified.

Howard, Daniel↗

Dynamic analysis of fully constrained Cable-Driven Parallel Robots for automated prefabricated component installation

This paper presents a dynamic analysis and validation framework to assess a fully constrained six-anchor Cable-Driven Parallel Robot (CDPR) for automated installation of prefabricated facade components. Compared with conventional eight-anchor systems, the six-anchor configuration simplifies setup and reduces cost, but it also reduces control authority, shrinks the wrench-feasible workspace, and tightens orientation limits. Consequently, it is unclear a priori whether dynamically feasible trajectories exist to move the end effector from pickup to the facade. A constrained trajectory optimization is formulated to enforce the system dynamics, cable-tension bounds, and pose/velocity limits, and the framework is evaluated in simulation at three levels: (i) an idealized reference model, (ii) a lab-scale prototype model incorporating measured anchor misalignments and identified damping, and (iii) a full-scale three-story building model with load decomposition for structural feasibility checks. Across these scenarios, the analysis shows that optimal, constraint-satisfying trajectories exist that move the end effector from pickup to installation while maintaining a near-plumb, level orientation at the final pose. Collectively, this multi-scale dynamic analysis and validation framework supports the deployment readiness of the six-anchor CDPR and provides a prototype-based sensitivity case study of how measured anchor placement deviations affect feasibility.

CDPR↗

Characterization of wood fiber insulation for the development of wood fiber-insulated panels (WIPs) for use in building envelope

Wood fiber insulation (WFI) was studied as an eco-friendly alternative for fossil-based building insulation, focusing on its use in new wood fiber-insulated panels (WIPs). Rigid WFI boards with densities of 110, 140, and 180 kg/m³, including a 140 kg/m³ variant without paraffin wax, were evaluated. Key properties investigated included porosity, water vapor transmission, liquid water adsorption, and thermal conductivity. The porosity ranged between 85 and 92%, primarily influenced by density. Water vapor permeability ranged from 65 to 90 ng·s-1m-1Pa-1, while liquid water absorption was between 2.5 and 20% by volume, influenced by both wax and density. The thermal conductivity coefficient ranged from 0.038 to 0.055 W/(m·K). Bond strength tests with WFI (140 kg/m³ with wax) laminated to various materials using structural adhesives showed tensile perpendicular-to-grain strengths of 10 to 16 kPa and shear strengths of 60 to 90 kPa, with failure only occurring within the WFI. It was concluded that WFI is a promising material for novel WIPs, offering competitive hygrothermal properties and compatibility with structural adhesives. However, its bio-based nature suggests variability and complexity, necessitating further rigorous testing in various climates and in more complex assemblies.

Materials Science↗

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]↗

Exploring Modeling Options and Conversion of Average Response to Appropriate Vibration Envelopes for a Typical Cylindrical Vehicle Panel with Rib-stiffened Design

Although applications for Statistical Energy Analysis (SEA) techniques are more widely used in the aerospace industry today, opportunities to anchor the response predictions using measured data from a flight-like launch vehicle structure are still quite valuable. Response and excitation data from a ground acoustic test at the Marshall Space Flight Center permitted the authors to compare and evaluate several modeling techniques available in the SEA module of the commercial code VA One. This paper provides an example of vibration response estimates developed using different modeling approaches to both approximate and bound the response of a flight-like vehicle panel. Since both vibration response and acoustic levels near the panel were available from the ground test, the evaluation provided an opportunity to learn how well the different modeling options can match band-averaged spectra developed from the test data. Additional work was performed to understand the spatial averaging of the measurements across the panel from measured data. Finally an evaluation/comparison of two conversion approaches from the statistical average response results that are output from an SEA analysis to a more useful envelope of response spectra appropriate to specify design and test vibration levels for a new vehicle.

Harrison, Phil↗

Evaluation of the Energy, Hygrothermal, and Thermal Capacity Performance of Cross-Laminated Timber

Cross-laminated timber (CLT) construction is gaining momentum in the US because it offers multiple advantages over traditional construction methods. Benefits that have received the most attention focus on constructability, the environment, and protection (e.g., blast resistance), although CLT construction is likely to offer other benefits, as well. Still, these have not been studied at length because such evaluations are costly, requiring long-term assessments in an actual building and specialized technical knowledge. Among the possible benefits, CLT construction likely provides a higher-performing building envelope. Using CLT panels to enclose a building means fewer joints in the opaque envelope than what is required in traditional stick-framed construction. Fewer joints mean fewer locations where the air- and water-resistive barrier (WRB) could be compromised; thus, a CLT building enclosure may require less maintenance and have a longer lifespan than a traditionally built structure because of fewer air and water leaks. In addition, CLT’s thermal mass moderates indoor temperatures, allowing the heating, ventilation, and air conditioning (HVAC) system to operate more efficiently during peak hours, reducing operational energy consumption throughout the lifetime of the CLT building (Salonvaara et al., 2022). Furthermore, more stable indoor temperatures can increase occupant comfort. The CLT’s thermal mass can also reduce energy costs by adjusting to utility time-of-use pricing without affecting occupant comfort. The ability of CLT buildings to bridge periods without HVAC operation prepares them for future grid interaction and provides a certain level of resilience against power outages. Researchers have attempted to quantify these benefits; however, their work is based on simplified simulations with numerous assumptions. To correctly understand the benefits, an actual building must be monitored. Therefore, information needs to be gathered on indoor and outdoor temperatures, HVAC energy consumption, thermostat setpoints, temperatures, and thermal transport in CLT components to comprehend how these parameters are affected by the CLT’s thermal mass. These data are needed to reduce the number of assumptions and calibrate simulation models to optimize HVAC controls to minimize overall energy consumption, reduce energy use and higher fees during peak demand, and maintain occupant comfort. Additionally, the calibrated simulation model allows the optimization exercise to be repeated in various US climates. Potential benefits can be tailored to buildings in various locations, and decisions can be made on where CLT construction could be most advantageous. Furthermore, monitoring and simulation results are needed to evaluate the durability of the CLT structures in different climates. This project’s researchers gathered information to help understand and quantify the benefits of CLT buildings concerning operational energy, moderated indoor temperatures, and comfort; the dynamic operation to provide grid services; and resilience in times of power outage. Through the corroboration of simulation models with real-world measurements, this study paves the way for extrapolating findings to other climatic zones and building typologies, thereby broadening the understanding of CLT’s multifaceted benefits and reinforcing its position as a material of choice in sustainable construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Dynamic Modeling, Trajectory Optimization, and Linear Control of Cable-Driven Parallel Robots for Automated Panelized Building Retrofits

The construction industry faces a growing need for automation to reduce costs, improve accuracy and productivity, and address labor shortages. One area that stands to benefit significantly from automation is panelized prefabricated building envelope retrofits, which can improve a building’s energy efficiency in heating and cooling interior spaces. In this paper, we propose using cable-driven parallel robots (CDPRs), which can effectively lift and handle large objects, to install these panels. However, implementing CDPRs presents significant challenges because of their nonlinear dynamics, complex trajectory planning, and precise control requirements. To tackle these challenges, this work focuses on a new application of established control and trajectory optimization theories in a CDPR simulation of a building envelope retrofit under real-world conditions. We first model the dynamics of CDPRs, highlighting the critical role of damping in system behavior. Building on this dynamic model, we formulate a trajectory optimization problem to generate feasible and efficient motion plans for the robot under operational and environmental constraints. Given the high precision required in the construction industry, accurately tracking the optimized trajectory is essential. However, challenges such as partial observability and external vibrations complicate this task. To address these issues, a Linear Quadratic Gaussian control framework is applied, enabling the robot to track the optimized trajectories with precision. Simulation results show that the proposed controller enables precise end effector positioning with errors under 4 mm, even in the presence of external wind disturbances. Through comprehensive simulations, our approach allows for an in-depth exploration of the system’s nonlinear dynamics, trajectory optimization, and control strategies under controlled yet highly realistic conditions. The results demonstrate the feasibility of CDPRs for automating panel installation and provide insights into their practical deployment.

CDPR↗

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]↗

Energy Efficiency Assistance for Galena Alaska

The City of Galena sits along the north bank of the Yukon River with no road access. Temperatures regularly reach negative 20°F in the winter and sunlight extends for up to 21 hours a day in the summer. Galena’s 400 residents, including members of the Koyukuk Athabascan culture, primarily use fuel oil and locally forested wood for heating and electricity generation. Because these resources are costly to obtain, local households have a high energy burden, spending 7% of their annual income on energy (averaging $4,000 per year). To reduce this burden, the City of Galena joined the U.S. Department of Energy’s (DOE) Remote Alaska Community Energy Efficiency (RACEE) Competition, where they received financial and technical assistance to implement energy savings solutions across their community, including building envelope improvements, solar panels, and LED lighting. Additionally, Galena installed new energy monitoring equipment to continue measuring the impacts of this work beyond the RACEE project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Loading tests of a wing structure for a hypersonic aircraft

Room-temperature loading tests were conducted on a wing structure designed with a beaded panel concept for a Mach 8 hypersonic research airplane. Strain, stress, and deflection data were compared with the results of three finite-element structural analysis computer programs and with design data. The test program data were used to evaluate the structural concept and the methods of analysis used in the design. A force stiffness technique was utilized in conjunction with load conditions which produced various combinations of panel shear and compression loading to determine the failure envelope of the buckling critical beaded panels The force-stiffness data did not result in any predictions of buckling failure. It was, therefore, concluded that the panels were conservatively designed as a result of design constraints and assumptions of panel eccentricities. The analysis programs calculated strains and stresses competently. Comparisons between calculated and measured structural deflections showed good agreement. The test program offered a positive demonstration of the beaded panel concept subjected to room-temperature load conditions.

Fields, R. A.↗

Large area, low cost solar cell development and production readiness

A process sequence for a large area ( or = 25 sq. cm) silicon solar cell was investigated. Generic cell choice was guided by the expected electron fluence, by the packing factors of various cell envelope designs onto each panel to provide needed voltage as well as current, by the weight constraints on the system, and by the cost goals of the contract.

Michaels, D.↗

Repeated buckling of composite shear panels

Failures in service of aerospace structures and research at the Technion Aircraft Structures Laboratory have revealed that repeatedly buckled stiffened shear panels might be susceptible to premature fatigue failures. Extensive experimental and analytical studies have been performed at Technion on repeated buckling, far in excess of initial buckling, for both metal and composite shear panels with focus on the influence of the surrounding structure. The core of the experimental investigation consisted of repeated buckling and postbuckling tests on Wagner beams in a three-point loading system under realistic test conditions. The effects of varying sizes of stiffeners, of the magnitude of initial buckling loads, of the panel aspect ratio and of the cyclic shearing force, V sub cyc, were studied. The cyclic to critical shear buckling ratios, (V sub cyc/V sub cr) were on the high side, as needed for efficient panel design, yet all within possible flight envelopes. The experiments were supplemented by analytical and numerical analyses. For the metal shear panels the test and numerical results were synthesized into prediction formulas, which relate the life of the metal shear panels to two cyclic load parameters. The composite shear panels studied were hybrid beams with graphite/epoxy webs bonded to aluminum alloy frames. The test results demonstrated that composite panels were less fatigue sensitive than comparable metal ones, and that repeated buckling, even when causing extensive damage, did not reduce the residual strength by more than 20 percent. All the composite panels sustained the specified fatigue life of 250,000 cycles. The effect of local unstiffened holes on the durability of repeatedly buckled shear panels was studied for one series of the metal panels. Tests on 2024 T3 aluminum panels with relatively small unstiffened holes in the center of the panels demonstrated premature fatigue failure, compared to panels without holes. Preliminary tests on two graphite epoxy shear panels with small holes in the center showed no similar fatigue life degradation and no shift in failure mode. Further tests on the effect of holes are in progress.

Singer, Josef↗

CAD-based Energy & Cost Models Prove Affordable Net Zero Energy Performance for WonderWindows + 24" On-center Framing

Windows are thermally the “weakest link” in the building envelope. Increasing the thermal resistance of windows can make buildings more energy efficient and reduce the cost of electricity needed for conditioning the building. The proper design and placement of framing can also help to reduce the thermal bridging that occurs near the window frame area. This study investigates the energy performance of multi-pane acrylic windows fitting 24" on-center framing. Initial parametric analysis is done for a single zone accessory dwelling unit (ADU). Then, an energy model was developed for three types of wood-framed buildings: townhomes, stacked flats and hotels. A whole building energy simulation is performed for each of these building types in hot-humid Houston, mixed-humid New York, and cold-humid Minneapolis climates. The results show up to a 39% reduction in heating, ventilation, and air-conditioning (HVAC) related electricity consumption for the cold climate compared to the Base case which has window and wall properties based on ASHRAE standard 90.1 2019. In the hot climate, a modest increase in electricity consumption was seen due to an increase in cooling electricity demand. The ADU achieved Net Zero Energy performance in all 3 Climate Zones despite having the highest exterior surface area-to-floor area ratio: the ADU also had the highest PV kW to floor area ratio compared to the other multi-story building types. The townhomes, hotel and stacked flats respectively met 73, 52 and 57 % of electrical use in Houston, 71, 48 and 56 % in New York, and 63, 40 and 53 % in Minneapolis from energy produced by rooftop solar. If 400 W solar panels are used instead of 320 W panel used for energy simulation, it is estimated that in the townhomes, hotel and stacked flats rooftop solar can meet 91, 65 and 71 % of electrical use in Houston; 89, 60 and 70% in New York, and 79, 50 and 66 % in Minneapolis. A preliminary evaluation of cost shows that such superior performance can potentially be achieved at less first cost with this 24"on-center solution than conventional construction. All the building types at the three locations used for simulation had net energy use intensity under 20 kBtu/sf/year with 320 W solar panel and under 17 kBtu/sf/year with 400 W solar panel. Further tailoring of building envelope R-values and window solar heat gain to particular Climate Zone locations for each building type shows promise in reducing the HVAC electricity use that comprises almost half of building energy use.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Meteoroid-detector deployment and pressurization systems

The Explorer 46 Meteoroid Technology Satellite (MTS) launched from Wallops Island, Va., August 13, 1972, was configured to fit within the Scout heat shield, 86.36 cm in diameter. In order to package within this envelope, the meteoroid bumper detector panels had to be rolled up unpressurized and secured to the spacecraft main structure. After the spacecraft was placed in orbit the panels were unrolled by a deployment system and inflated by a pressurization system.

Halliday, H. C.↗

Compressive Strength of 24S-T Aluminum-alloy Flat Panels with Longitudinal Formed Hat-section Stiffeners

Results are presented for a part of a test program on 24S-T aluminum alloy flat compression panels with longitudinal formed hat-section stiffeners. This part of the program is concerned with panels in which the thickness of the stiffener materials is 0.625 times the skin thickness. The results, presented in tabular and graphical form, show the effect of the relative dimensions of the panel on the buckling stress and the average stress at maximum load. Comparative envelope curves are presented for hat-stiffened and Z-stiffened panels having the same ratio of stiffener thickness to sheet thickness. These curves provide some indication of the relative structural efficiencies of the two types of panel.

Schuette, Evan H↗

Orbiter radiator panel solar focusing test

A test was conducted to determine the solar reflections from the Orbiter radiator panels. A one-tenth scale model of the forward and mid-forward radiator panels in the deployed position was utilized in the test. Test data was obtained to define the reflected one-sun envelope for the embossed silver/Teflon radiator coating. The effects of the double contour on the forward radiator panels were included in the test. Solar concentrations of 2 suns were measured and the one-sun envelope was found to extend approximately 86 inches above the radiator panel. A limited amount of test data was also obtained for the radiator panels with the smooth silver/Teflon coating to support the planned EVA on the Orbiter STS-5 flight. Reflected solar flux concentrations as high as 8 suns were observed with the smooth coating and the one-sun envelope was determined to extend 195 inches above the panel. It is recommended that additional testing be conducted to define the reflected solar environment beyond the one-sun boundary.

Howell, H. R.↗