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Design and assembly automation of the Robotic Reversible Timber Beam

Article  in  Automation in Construction · March 2021

DOI: 10.1016/j.autcon.2020.103531

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Design and assembly automation of the Robotic Reversible Timber
Beam

ABSTRACT
The field of architecture is referring to wood as a sustainable solution for satisfying the need for new
buildings while offsetting carbon emissions. This paper presents an original workflow for the automation
from design to ​layered robotic assembly of reversible timber structures, aided by human-robot
collaboration. An advanced digital design workflow for non-standard timber structures is established,
shifting the focus towards the assembly of a kit of discrete wood elements into larger configurations that
can be reconfigured in time. Linked to this, collaborative robots are employed for grasping, positioning
and fixing of discrete timber elements, with the introduction of a multi-phase end effector that connects
wood elements through reversible joinery. The various developments are applied to a research
demonstrator which crystallizes the various design, constructional, and manufacturing inputs into a
physical output, which is discussed from multiple viewpoints, in order to delineate relevant areas for
future studies.

Keywords: R​ obotic Timber Construction, Layered Assembly, Reversible Structure, Design automation,
Digital Twin, Human-Robot Collaboration

1. Introduction the integration of various feedback devices [4]. In

Our planet is currently experiencing an
unprecedented climate emergency. Increasing
emissions of carbon dioxide, unanimously
recognized as the main agent of climate change,
are requiring a shift towards more sustainable use
of natural materials in the construction industry.
For most countries, wood represents an ideal
solution to the problem, being a natural carbon
store, besides being a renewable, lightweight
construction material. As part of a more
generalized effort in evolving digital techniques
for wood-based architecture, this piece of research
focuses on enhancing automation in the robotic
construction of carbon-efficient wood structures,
targeting circularity of resources in particular. The
increasing use of robotic manipulators is in fact
promoting higher fabrication flexibility and design
freedom, which is well coupled with advances in
computational design. The employment of
multi-axis robotic cells enables, on one hand, the
versatile ​digital fabrication of wood elements for
construction, such as structural components with
integrated joinery [1], complex and curved beams
with mass timber [2], and the manufacturing of
unprocessed wood logs to eliminate laborious
industrial processing [3]. On the other hand,
methods for ​robotic ​assembly a​ re emerging,
adding possibilities for non-standard systems
made of generic wood profiles, where the use of
robots enables precision and efficiency through
spite of promising perspectives, the research
shows that assembly tasks are predominantly
relying on manual operations for joining various
elements [5].
In this work, we describe the implementation of a
new concept of timber construction based on an
approach to robotic assembly, with a multi-phase
procedure that involves the precise grasping,
spatial manipulation and positioning of individual
timber elements, and the automatic application of
reversible connections, i.e. steel bolts and nuts.
The process follows an additive logic based on
layered assembly, which is here associated with a
computational workflow for the efficient design of
structures made of reusable timber elements.
These can be assembled, disassembled, and reused
for different structural configurations, extending
the material life-cycle, and in turn, minimize the
carbon footprint of a structure.
2. Background
Construction, as we know it today, is
characterized strongly by inefficiency and a low
level of automation [6]. In the last decade,
architectural experimentation aided by the
employment of computational means has triggered
a new digital turn [7], pivoting around the
possibilities of automating building processes [8].
More recently, an approach linking robotic

Pre-print version (Published article DOI: 10.1016/j.autcon.2020.103531) 1

fabrication with discrete design has emerged,
relying on combinatorial logics to develop
articulated design out of relatively simple modular
elements [9]. Driven by the idea of assembly
automation on one side, and economy of resources
on the other, the relevance of the ​discrete timber
architecture is growing, with built examples in the
architecture of Kengo Kuma [10], in
contemporary experiments at architectural scale
[11], as well as in research prototypes [12-14].
In parallel, research in architectural robotics has
stimulated key advancements in assembly
automation [15]. Gramazio Kohler Research at
ETH investigated the layered robotic assembly of
building elements such as walls, pavilions, and
ceilings based on a stratification of custom
elements joined with the use of wood adhesives,
nails, or non-reversible screws [16,17]. In the
professional practice, Studio RAP built a robotic
cell to compose a wood partition out of a large
number of wood parts obtained from industrial
scrap material [18]. Further studies from ETH
involved (2) the spatial assembly of building
portions with timber blocks, involving cutting,
milling, drilling, and nailing of timber elements
[19-21]. Recent approaches have also involved
human-robot interaction based on haptic feedback
through force-torque sensing [22,23] and
robot-robot collaborative assembly [24-26], to
overcome the inherent complexity of wood
construction - i.e. material irregularity, complex
mechanical conditions, and unstable
morphological features.
3. Research Aim and Approach
In this research, we develop an automated process
for the design and assembly of ​robotic reversible
timber structures. Reversible constructions can be
assembled, updated, disassembled, and
reassembled in time - fundamentally extending the
life-cycle of the timber material and consequently
preserving its carbon storage for a longer time.
Reversibility is a key feature in enabling a circular
use of resources, and it is here implemented both
at the design and process level, utilizing joinery
that is screwed automatically by robotic arms, a
feature that is here introduced for the first time in
Pre-print version (Published article DOI: 10.1016/j.autcon.2020.103531)
construction applications. Moreover, our aim is to
seamlessly connect the design and construction
phases, by establishing a continuous digital
workflow.
In the following sections, the approach is
documented in reference to an experimental
design-make case study developed through a
computational workflow. It integrates
performance-driven voxel-based design, digital
fabrication of a construction kit, and robotic
assembly. In the development, we rely on two
fundamental concepts: the first one is ​the use of an
extended ​digital twin which connects the phases of
design/optimization, simulation, and real-world
assembly through bi-directional communications;
the second one is ​human-robot collaboration to
provide immediate assistance to the robot,
increasing the overall efficiency [27].
3.1 Computational workflow and digital twin
The entire project is based on a computational
workflow (Fig.1) that connects design, fabrication
and robotic assembly, in a seamless process [28].
Four main phases are involved: ​voxel-based
design and structural optimization (1),​ where
building elements are designed, boundary
conditions are defined, and a structural
optimization is performed; ​construction kit design
and digital fabrication (2), ​where a c​ onstruction
kit i​ s designed with combinatorial features and
timber elements are CNC machined, including
features for robot handling; ​performance-based
design discretization ​(3)​, where the structural data
is converted into specific aggregations of timber
blocks to form tectonic configurations; The
workflow is then connected to the ​robot
simulation and control phase ​(4)​, where the actual
assembly process happens in connection with the
existing geometric, material, and simulation data
generated in the previous phases. A virtual replica
of the whole process is recreated and linked as a
digital twin of the real-world process [29], through
location detection and force-feedback. Integration,
simulation, and robot control are run directly from
the design environment.
2
 Fig. 1.​ Computational workflow scheme which integrates design, fabrication and assembly processes.
3.2 Construction kit design and digital
fabrication
The construction system for robotic layered
assembly is studied in parallel to the global design
and optimization process. The approach follows a
predetermined logic of modularity and
aggregability, similarly to a LEGO kit. Universal
and generic elements can be assembled together to
form functional building parts, and virtually be
recombined for an infinite amount of times. The
aggregation is based on shingled discrete elements
that are joined across layers, following any
direction with angles multiples of 45°. Through
empirical tests, the geometry of these elements
was optimized for reversible joinery and CNC
prototyping. As a result, a construction kit
consisting of thirteen pinewood elements was
conceived (Fig.2).
Fig. 2. The developed construction kit consists of thirteen
discrete elements which can be aggregated in various modes
Pre-print version (Published article DOI: 10.1016/j.autcon.2020.103531)
The elements have an elongated arrow-like shape
aligned with the fibre orientation, with
convex-convex and concave-convex ends, and a
reversed T-shaped cross-section to ensure
free-of-collision robot grasping. They present
holes patterns that allow for different
combinatorial aggregations and confer higher
design freedom compared to typical modular
elements​ ​(Fig.3).
Fig. 3.​ Possible aggregations between four types of blocks
The construction blocks were machined with an
industrial CNC router out of standard pine battens
(Fig.4), whose cross-section dimensions matched
the dimensions of the voxel units used in the
computational design and discretization processes.
This machinic process allows for high-speed
production, high-precision and repeatability,
which are fundamental for achieving a consistent
3
assembly process based on a large set of elements.
The machining toolpath was optimized with a
CAD/CAM simulation module to reduce the
fabrication time, and achieve the desired outcome.
In the resulting milling setup, each block took
about two minutes to be processed, including
cutting, milling, drilling and chamfering.
Fig. 4.​ CNC milling process of one construction block
3.3 Voxel-Based Design and Structural
Optimization
The computational design-to-assembly workflow
was fundamentally developed within the
Grasshopper environment [30]. Initially, a
three-dimensional Finite Element Analysis (FEA)
and Topology Optimization (TO) was performed
using the Millipede plug-in [31] as the main
calculation engine. Live load and self-weight were
applied in the optimization of a four-meter long
beam structure, constrained at both ends.
Subsequently, the resulting TO layout from
Millipede has been converted through the
Monolith plug-in [32] into a voxel-based field
with stored attributes such as principal stress
trajectories and Von Mises stress magnitudes. The
first ones are translated into discrete orientation
values 0, 45, 90 and 135 degrees, matching the
orientation of the construction kit, and in turn, the
orientation of the wood fibres to ensure an ideal
load-bearing behaviour (Fig.5). The second one
provides information to sort the components
according to their density - the higher ones are
placed where higher stiffness is required.
Neighbouring voxels along one axis that have the
same attributes are grouped and converted into the
discrete wood elements previously described.
Pre-print version (Published article DOI: 10.1016/j.autcon.2020.103531)
Fig. 5.​ Discretization of the principal stress trajectories into
four predefined angles.
Unlike existing examples of TO for robotic timber
construction [21] which are based on specific and
customized elements, our approach generates an
optimal design output out of generic and reusable
elements. Such structural, formal and operational
flexibility relies on the implementation of versatile
and collaborative robot manipulators coupled with
automated screwing, where highly complex
structures are obtained without the need for
additional material transformation.
3.4 Performance-Oriented Design
Discretization
In this phase, the design is finalized into a 3D
model with detailed information on the type,
number and position of 696 building blocks, and
specifics for connecting them with a joinery
pattern based on 1464 steel bolts among 3437
possible connections. An algorithm evaluates for
every single block the possible connections with
the adjacent ones and provides a solution to form a
continuous solid structure with a minimized
number of bolts (Fig.6). This last information is
utilized to prepare the building blocks for the
assembly with the embedding of steel nuts.
Furthermore, an algorithm for local stability-check
of each block during the assembly is implemented
and temporary supporting blocks are generated
where needed. The overall description of the
digital design data is linked directly to the robotic
assembly process​, ​allowing for an efficient and
seamless connection between design and making.
4

Fig. 6.​ An algorithm for connections layout optimization was
implemented, to compute the number and position of bolts to
be used in the assembly.
4. Robotic assembly of reversible
timber structures
4.1 Robot setup
A flexible robot cell was conceived for layered
robotic assembly. This consists of modular
welding tables (120x80 cm) which can be
reorganized easily to adapt the fabrication to
different types of structures. In this specific case,
we adopted a layout with a fabrication zone of
400x100 cm. The engraved grid on the table
working plane is used for calibration and as a
referencing system to relate geometrically the
physical and digital setup. It also provides a quick
means to attach various tools and equipment,
making the setup highly flexible and adaptive to a
range of fabrication conditions with an inherent
precision (Fig.7).
Fig. 7. ​The fabrication setup that has been used for layered
robotic assembly of the case study
An auxiliary zone of the tables hosts the robots,
screw holders, and 3D printed fixtures material
feeding. The 6-axis robotic arms are collaborative
Universal Robots (UR) which were installed to
cover jointly the required assembly area. These are
equipped with a ​multi-phase end-effector (​ Fig.8)​,
which can be utilized in various assembly and
manipulation tasks. The tool consists of an ​electric
gripper (1) to handle, manipulate and position the
timber pieces with controllable finger stroke and
Pre-print version (Published article DOI: 10.1016/j.autcon.2020.103531)
gripping force, an ​automatic screwdriver (2) with
an exchangeable screw tip and torque-based
sensors. The screwdriver is mounted on a
custom-made ​tool flange (3) perpendicular to the
gripper [33] in order not to obstruct the gripper
during its operation, and at the same time
eliminating the need for time-consuming tool
exchange processes. Additionally, a customized
screw holder with an integrated magnet (4) was
designed, 3D printed and attached to the
screwdriver bit (5) in order to handle and insert
M4 steel bolts. An ​interface for human interaction
(6) is also integrated to enable human assistance
during the screwing process. This custom feature
can potentially be mapped to enable locally a wide
range of robot functions and commands.
Fig. 8.​ The multi-purpose end-effector consists of the two
principal tools for assembly: an electric gripper and an
industrial screwdriver which are alternated during the assembly
process.
4.2 Robot Simulation and Control
A direct link between the design process and the
robotic assembly is established in a parametric
way through the HAL Robotics Framework
plug-in for Grasshopper [34], where geometric
features of the building blocks are translated into
target planes and further to robot commands. The
robotic toolpath generation is based on two groups
of reference target points: the ​pick-and-place
operations are defined by the centre points of each
block’s top face both in the ​picking and ​placing
positions, and several intermediate points which
assure safe operation, i.e. a 100 mm offset in the
positive z-direction of the current picking target;
the middle point of the line which connects the
current picking target and its corresponding
placing target displaced in the positive z-direction
to distance of 200 mm from the current bounding
box of the so-far built structure; and a 100 mm
offset in the positive z-direction of the current
placing target. On the other side, the ​screwing
target planes are defined by the centre points of
the bottom side of each hole that requires a screw.
5
All points are represented in the robot’s
end-effector frame, i.e. tool centre point (TCP).
This information is directly conveyed from the
algorithm that solves the connections among the
different pieces (Section 3.4). The transfer of
robot commands is here based on a bi-directional
communication channel established between the
robot simulation within the parametric design
environment and the robot controller, providing us
with the capability of sending robot commands
and monitoring the assembly data in real-time,
thus closing the digital-twin loop respectively.
4.3 Robotic Assembly
The calibration between the simulation model and
the real workcell is done geometrically, based on
existing table reference features. In particular, the
geometrical relationship and distances between the
Siegmund working area, the robot, material
fixtures and the auxiliary tools are defined in the
digital twin environment based on the existing
Siegmund grid. This has significantly increased
the precision of the system and assembly
operations, considering the fact that no vision
feedback has been involved at this stage.
Fig. 9. a) Pick-and-place of the timber construction elements;
b) Robot’s screwing configuration and a human operator
switching to collaborative mode; c) Robotic screwing
procedure.
The process starts with the pick-and-place of the
timber construction elements utilized for building
the ​reversible timber beam​, as well as the
elements utilized for supporting the construction
temporarily during the assembly (Fig.9a). After
every block is placed to its specific position within
the structure, the screwing procedure is executed.
Firstly, the robot is moved into the predefined
screwing configuration. Secondly, the M4 screw is
picked from the 3D printed screw holder, which
acts as a magazine placed within the auxiliary
zone. Thirdly, the robot moves to the screwing
Pre-print version (Published article DOI: 10.1016/j.autcon.2020.103531)
location provided by the simulation and performs
the screwing operation. While the operation is
executed, robot signals such as ​tool position and
recorded forces​, are monitored and communicated
through the feedback loop. If the signals do not
match the defined assembly conditions, the system
prompts the human operator to intervene while
switching to collaborative mode (Fig. 9b). This
can happen when the force is too high, or when
the position deviates from the defined one in the
simulation due to material tolerances and
irregularities resulting from the milling process, or
shape changes resulting from fluctuations in the
moisture content of the material. In this scenario,
the human operator first switches the ​Wrist switch
1 to ​true,​ enabling the robots in-built free drive
mode. This mode enables the human to guide the
robot to the desired location of the hole. At the
location, the operator switches the ​Wrist switch 1
to ​false, i​ .e. disabling free drive and presses the
Wrist switch 2 button enabling the screwing
procedure from the demonstrated point of action.
In this procedure the screwdriver runs until a
preset torque of 50N is reached. Here as well the
robot signals are monitored (Fig.9c) in the same
way as with the automatic screwing procedure. If
the screw is successfully inserted and all the preset
conditions are met, the screwdriver stops and the
tool retracts from the assembly piece finalizing the
screwing procedure. Afterwards, the tool moves to
the next screwing location and executes the same
procedure. With this approach, we can account for
manufacturing inconsistencies in the wooden
blocks as well as nonuniformities in the wood
itself, i.e. the presence of knots, shrinkage or
expansion due to humidity and temperature
changes etc, with the help of human collaboration,
and still maintain a reliable screwing action (Fig.
10).
Fig. 10.​ Collaborative robotic assembly setup consists of two
UR robots and human assistance.
6
5. Results
In this project, we have successfully implemented
a novel approach for the design and manufacturing
of reversible timber structures, including the first
development of a robotic process to automate the
assembly of such construction. A prototype was
completed to demonstrate both the process and the
concept of reversible structure.
From a manufacturing point of view, our approach
combined the mutual advantages of serial
production and agile manufacturing, with the use
of high-precision CNC machining of a predefined
kit of timber blocks, coupled with the custom
assembly performed by collaborative robots in
direct connection with a design model (Fig.11).
With this experiment, we prove that custom and
carbon-efficient structures can be realized without
the need of material-intensive processes but
through the advanced aggregation of
pre-fabricated discrete elements.
Fig. 11.​ Close-up view of the structural prototype with digital
information overlay. The convoluted morphology is obtained
through the assembly of simple construction elements in a
specific assembly sequence.
A new robot cell design was developed for the
fabrication of reversible timber structures. In
terms of hardware, we integrated components such
as robots and screwdrivers, which are usually
found in industrial high volume production, into a
compact flexible workcell for assembly of parts
manufactured of nonuniform materials such as
wood. A multi-phase end effector was utilized
here for the first time, which avoids the need for
time-consuming tool exchange.
A successful workflow was established to link the
phases of design and optimization of custom
structures, with the actual robotic assembly.
Information and data exchange between the design
environment and real-world construction was
Pre-print version (Published article DOI: 10.1016/j.autcon.2020.103531)
established through a cyber-physical system. We
completed a robotic procedure for the assembly of
reversible timber constructions. The screwing
operation, in particular, required human assistance
as a result of building up tolerances along the
process, which is partly explained by the
hygroscopic nature of the material. This feature
was embedded actively as part of a more
generalized approach to collaborative
construction.
The overall process was applied successfully to
the realization of the experimental structure
Reversible Robotic Timber Beam (Fig.12). The
prototype itself is a proof-of-concept for a discrete
construction system that is based on layered
robotic assembly, which given the reversibility of
the joinery utilized, can evolve through time. In
addition, the robotic unscrewing was tested on a
few elements: the operation proved to be
mechanically possible but challenging to adopt on
a large assembly set because of the deviation that
was accumulated in comparison with the digital
model. The prototype was then demounted
entirely by hand and re-assembled successfully. A
total of 216 kg of CO​2 is stored within the
assembled building blocks. By demounting and
reutilizing them multiple times, the life-cycle and
carbon-storing time of the material is significantly
extended.
Fig. 12.​ The final prototype of Reversible Robotic Timber
Beam - a four-meter long beam structure consisting of 696
blocks connected through 1464 bolt-nut connections.
6. Conclusions and future outlook
This research is a proof-of-concept for reversible
robotic timber structures, a process which presents
several advantages for carbon-efficient
construction. While timber construction is
typically referred to as a sustainable material
solution, the use of design-specific elements in
current practice makes wood poorly reusable. In
7
this experimental approach, we proved that: (1) a
universal kit of wood elements can be used to
build geometrically optimized structures; (2)
reversible joinery can be utilized instead of glue or
nailing, enabling reconfigurability and reusable
construction; (3) collaborative robots can be
employed to automate entirely the assembly of
complex layered structures. These combined
features offer important perspectives for wood
construction automation, as well as possibilities
for a more circular use of material, which can be
reutilized indefinitely, retaining the stored carbon
for a longer time. Further studies will be directed
into various levels of investigation. The robotic
cell will be further developed by adding extra
degrees of freedom to extend the usable
workspace and realize larger construction
elements. In order to improve the reliability of the
system, we aim to introduce a feedback system
based on robot vision, for object detection,
compensation of tolerances, and real-time
assembly validation. More focused research on the
automation of the dis-assembly and reassembly
process of the structures will also benefit from
robot vision and expanded use of force-torque
sensors. Referring to the construction aspects, a
specialized study on shear-resistant joinery for
robotic assembly of discrete timber assemblies is
currently conducted. This will be fundamental in
understanding the mechanical behaviour of such
timber structures at a large scale, and ultimately to
evaluate the mechanical efficiency of this
approach in relation to existing techniques.
Acknowledgements
This research has been developed as an
interdisciplinary collaboration between CREATE
group and SDU Robotics from the University of
Southern Denmark. The work was developed with
the support of the SDU Industry 4.0 Lab. The
authors also wish to thank Takwa ElGammal and
Luca Breseghello for their contribution to the
development and fabrication processes.
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