HOOKE|ROBOTICS [2015-2016]
HOOKE
ROBOTICS Hooke|Robotics is an advanced fabrication lab developing innovative design & fabrication processes through a methodological approach. Situated at the AA’s Hooke Park woodland campus, our research includes developing a ‘smart’ programming environment for supporting and enhancing architectural applications.
www.hookerobotics.aaschool.ac.uk
FACILITIES
ROBOT DATA Robot: Kuka KR-150 (2000 series) Reach: 2700mm Max Payload: 150kg Controller: KR C2 Digital I/O: 10 Inputs, 10 Outputs Power: 24V and 240V Kuka Rotary Axis Integrated Robot Cell Dimensions 7m x 6m x 5m
Spindle
Chainsaw
Gripper
Max Speed: 24,000 rpm Max Cutter Diameter: 25mm Max Cutter length Available: 150mm
Chain speed Max Speed: 15.2 m/s Bar length: 16 inches Voltage: 230 V
Quantity: 2 Pneumatic Grippers - individually controlled Max length: 150mm
Rail & Trolley
7th/ Rotary Axis
Length of Rail: 5000mm Trolley length:1500mm Number of points: 3
Stock positioning: Horizontal
USER INTERFACE
Design
Toolpath for custom end-effectors
Inverse Kinematics
Custom algorithms using Grasshopper Script + Python
kukaPRC (Robots in Architecture) / Open Source Solutions
Easy to learn and use Parametric integration Multiple systems integration
Method 1
Method 1: Developed a bespoke custom programming package for chainsaw, milling router, hotwire cutter/ bandsaw, timber/ metal rod gripper written in python and using KUKAPRC on Rhinoceros 3d and Grasshopper 3d software platforms. There are three major advantages found using parametric robotic fabrication method: (a) Any solution can be quickly modified as the entire algorithm is parametrically defined; (b) Being an in-house developed tool it gives complete control to the fabricator where quick edits of the solution can be performed c) Compatibility issues of data can be prevented as all tasks could be performed in this single interface (d) Students can easily learn and adapt as the algorithm was developed on familiar software platforms.
Design
Toolpath for custom end-effectors Custom algorithms using Grasshopper Script + Python
Inverse Kinematics
RobotMaster
Robust and stable solution No IK problems Smooth production
Method 2
Method 2: Although method one is easy to learn, quicker to generate toolpaths and fleixibile to use, it was still not a robust method and did not provide solutions for robot singularities, robot axis limits, complex machining process for complex geometries. Another two-stage process was developed using two different interfaces, which offered a robust and automated output: First, on the Grasshopper platform, the custom toolpaths which included handling and manipulation of data were executed. Then, a post processor was written on the same platform to generate XYZIJK of the toolpath in Automatically Programmed Tool (APT) code format. The format was represented in XYZIJK, where XYZ defines the Cartesian coordinates of Tool Centre Point (TCP) and IJK defines the vector for tool orientation. Thereafter, the code is imported into the Robotmaster using the Robotmaster Import Utility Tool.
Research + Build Project Wood Chip Barn 2015 A fabrication methodology through which the inherent form of large non-linear timber components was exploited in the Wood Chip Barn project by Design + Make programme at the Architectural Association’s Hooke Park campus. Twenty distinct Y-shaped forks are employed with minimal machining in the construction of a structural truss for the building. Through this workflow, low-value branched sections of trees are transformed into complex and valuable building components using non-standard technologies. Computational techniques including parametric algorithms and robotic fabrication methods were used for execution of the project. Custom algorithms, codes and post-processors were developed and integrated with existing software packages to compensate for drawbacks of industrial and parametric platforms. The project demonstrated and proved a new methodology for working with complex, large geometries which also resulted in a low cost, time and quality efficient process.
Workshop Introduction to Robotic Fabrication
Spring 2016 Flexibility and adaptive qualities of 6 axis industrial arm has made it to be part of the architect’s toolset not only in the prototyping phase but also in the creative thought process. The workshop gave a brief introduction to robotic fabrication using 6 axis robot - KUKA KR 150 at Hooke Park’s Robotic Lab. The workshop was conducted in two stages: • The first phase consisted of an initial familiarisation with the robot arm through presentations, live demonstrations and tutorials for offline programming. • The second phase allowed the participants to develop their own design and its assembly process using the gripping tool as a team effort. The main aim of the workshop was not only to educate how to use the robot as a fabrication tool but also illustrate how to design as an architect with the robot.
Workshop Robotic Fabrications Summer 2016 Merging expert knowledge of timber construction with cutting-edge robotic fabrication technologies the workshop explored the creative potential of prototyping complex and large-scale timber structures with digital tools resulting in the construction of a temporary foundry building for the Hooke Park Campus. The chainsaw was wielded by the large KUKA KR 150 robot which exhibited an augmented level of precision and control. Principles of ancient craft and traditions of Japanese joinery were digitally interpreted -and whilst preserving the poetry, ritual and sensitivity, they were translated into a highly choreographed movement pattern or toolpath for the robot. Through rigorous physical testing, complex connection details were created utilizing the extraordinary precision and flexibility of multi-axis robotic machining. The ambition of the course was twofold. Firstly to provide a pro-active introduction to the exciting world of robotics. The first phase consisted of an initial familiarization with the robot arm through online programming using the teach pendant. After getting acquainted with the robot exploration, offline programming methods using the software and robot machining strategies were developed which allowed and assisted with the generation of suitable toolpaths for the designed geometries. Secondly the strategies for fabrication was based upon the ancient traditions of Japanese joinery. The visiting school focused on translating this dexterous craft full of poetry and skill into a movement pattern and choreography for the robot. This led to the on-site fabrication and assembly of the components for the construction of a prototype foundry building at Hooke Park
Workshop DLAB Summer 2016 The workshop developed an innovative strategy to construct three-dimensionally interwoven concrete structures by integrating computational design, material research and robotic fabrication techniques. A research methodology was structured around a set of experiments in line with the research objectives. Initial computational form-finding techniques explored the generation of a network of interwoven elements via a bundling algorithm. Simultaneously, an automated fabrication process was developed, where custom shaped steel reinforcement bars were bent using 6 axis robot(KUKA KR- 150), custom built jig and pneumatic grippers. The bending jig system comprised 3 different bending discs, with radii of 150 mm., 100mm., 50 mm and a pneumatic gripper for securing one end of the steel rod in position (Figure 02, 03 and 04). Rod bending process guided a set of constraints which had direct feedback on the computational form-finding process. Bundling algorithm outcomes were optimized via a custom-built Python scripts evaluating the curvature of each element at specified domain intervals, finding closest curvature value in alignment with one of the radii stated above, and rebuilding the geometry such that the final output was a series of lines and arcs with variable bending angles. Through the analysis of rod bending strategies in traditional manufacturing industries that were well-documented and established, the research aimed to develop a novel approach by the reduction of mechanical parts for controlling the desired output form. This goal was achieved by an intelligent robotic toolpath, developed in KUKA prc in conjunction with Python scripting, where the necessary material considerations, including tolerances and spring-back values, were integrated in the bending motion strategies through a systematic series of mathematical calculations in line with physical tests. The research intends to incorporate simple mechanical tools and cost-effective fabrication methods with the complexity embedded in generative form-finding processes, geometrical rationalization, and robotic tool-path creation that integrates material constraints in future.
Workshop DLAB Summer 2015 The workshop builds upon the material behavior research that investigated the fabrication and construction of double-curved complex geometries in applying generative design techniques and robotic milling strategies. Robotic fabrication processes in design allow for moving away from a direct design-to-production approach, whereby the final outcome is predefined and fabrication solely offers a means to an end. The tooling path of the robotic arm serves as a direct visual connection between the global geometry and local surface manipulation; therefore, the robotic end effector plays a crucial role as a design tool in the generation of localized surface textures on the global configuration. Throughout the design, fabrication, and assembly processes, the interactive associations between different simulation software have been a key driver in recognizing the ways of integrating architectural criteria with the structural performance of the pavilion. Overall, the research aims to illustrate the architectural possibilities of using concrete in a non-conventional way with limited resources and period of time by creating strong associations between computational design methodologies and digital fabrication processes.