Foundations of an Automated Modular Spraying System (AMSS) for Construction Materials

Foundations of an Automated Modular Spraying System (AMSS) for Construction MaterialsThis paper introduces the concept of an Automated Modular Spraying System (AMSS) for manifold building material applications.AMSS would feature interchangeable spraying modules for different viscous materials, integrating with robotic carriers for flexible deployment.Optimizing process parameters through experimental research and CFD simulations for different materials and integrating sensory detection and control mechanisms would ensure precise coating, reduce material waste, and enhance safety.The versatile AMSS offers practical solutions for automating material application, improving construction practices, and advancing industry sustainability. Introduction to Construction Material ApplicationThe application of paints, primers, floor and roof coatings, surface fillers, and other construction materials related to this category has gained massive importance because it is through their application that structures are provided with stability, durability, and aesthetic appeal.The application of these materials enhances the preservation of the integrity of buildings over time with waterproofing and visual effects; thus, there is a need for controlled use that will lead to optimized results during construction.Manual rollers or brushes have long been preferred for the building industry due to their simplicity and adaptability.Still, more often than not, they tend to create irregular applications, labor-intensive operations, and wastage, especially in larger and complicated projects [10].Increased material loss and longer duration periods are usually collateral results.Mechanical hand-operated spraying systems quickly emerged addressing these issues by offering higher coverage, faster application rates, and a more even coating, making them far more cost-effective on larger projects [17].Yet, handheld mechanical sprayers have some drawbacks: the irregularity of application, labor shortage, and health risks from overspray and aerosols.These issues underscore the need for safer and more efficient application methods.Recent advancements in automated spray systems represent a significant leap in construction material application.These systems could offer faster, more accurate application, greater uniformity, and reduced labor.The growing interest in advanced spray systems is evident from solutions like those from Apellix and Carlo Ratti Associati, which use drones for spraying [1], [18].This research aligns with industrial efforts to improve productivity and tackle existing challenges in paint application only.The present-day generation of robotic systems for applying building materials is limited to single-material applications, like paint or plaster, and has a narrow scope [2], [11-14].They are not modular; spray heads are integrated into fixed equipment carriers, which restricts their versatility and increases their cost.However, most research currently focuses more on the study of device carriers and environmental recognition algorithms, with less emphasis on the process parameter control of various materials [19], [20], [23].The current technical problems include overspray, unsatisfactory surface quality control, and sharp-edged applications without masking.The automation of surface quality evaluation is also relatively unexplored [6], [9], [16].Unlike traditional spraying devices, automated sprayers can handle