A mortar applicator includes: a duct; a piston movably mounted within the duct, dividing the duct into first and second variable volume chambers; a pump fluidly connected to the first variable volume chamber; a nozzle operatively connected to a first end of the duct to discharge mortar contained in the first variable volume chamber; and a motor operatively connected to the piston. A rack and pinion assembly operatively connects the motor to the piston and includes a rack configured to drive the piston and a pinion connected to the motor. In a discharge mode, the motor drives the rack and pinion assembly, moving the piston to force mortar through the nozzle opening to discharge mortar from the mortar applicator. In a refill mode, the pump fills the first variable volume chamber with mortar, forcing the piston to retract. The rack moves with the piston in the discharge and refill modes.

A mortar applicator includes: a duct; a piston movably mounted within the duct, dividing the duct into first and second variable volume chambers; a pump fluidly connected to the first variable volume chamber; a nozzle operatively connected to a first end of the duct to discharge mortar contained in the first variable volume chamber; and a motor operatively connected to the piston. A rack and pinion assembly operatively connects the motor to the piston and includes a rack configured to drive the piston and a pinion connected to the motor. In a discharge mode, the motor drives the rack and pinion assembly, moving the piston to force mortar through the nozzle opening to discharge mortar from the mortar applicator. In a refill mode, the pump fills the first variable volume chamber with mortar, forcing the piston to retract. The rack moves with the piston in the discharge and refill modes.

A manipulator configured for transferring a block having a core, the manipulator includes an end effector including an elongated member including a tip; and a resilient member configured for assuming a first state in which the resilient member has a first hardness and first size and a second state in which the resilient member is configured for assuming a second state in which the resilient member has a second hardness and second size, the resilient member is disposed on the tip, wherein the elongated member is configured to be disposed such that the tip is disposed within the core and the resilient member is disposed in the first state before the resilient member is disposed in the second state to engage the core and the elongated member is moved to transfer the block.

A mortar applicator includes: a duct having a first end and a second end; a piston movably mounted within the duct, the piston dividing the duct into first and second variable volume chambers on opposite sides of the piston; a piston actuator operatively connected to the piston, the piston actuator being operable to move the piston within the duct; a nozzle assembly located at the first end of the duct, the nozzle assembly having a tip defining a nozzle opening in fluid communication with the first variable volume chamber to discharge mortar contained therein; and a cover member selectively movable between an open position and a closed position to respectively allow and prevent mortar to be discharged through the nozzle opening; a cover member actuator operatively connected to the cover member, the cover member actuator being operable to move the cover member between the open position and the closed position.

A mortar applicator includes: a duct having a first end and a second end; a piston movably mounted within the duct, the piston dividing the duct into first and second variable volume chambers on opposite sides of the piston; a piston actuator operatively connected to the piston, the piston actuator being operable to move the piston within the duct; a nozzle assembly located at the first end of the duct, the nozzle assembly having a tip defining a nozzle opening in fluid communication with the first variable volume chamber to discharge mortar contained therein; and a cover member selectively movable between an open position and a closed position to respectively allow and prevent mortar to be discharged through the nozzle opening; a cover member actuator operatively connected to the cover member, the cover member actuator being operable to move the cover member between the open position and the closed position.

A method for assembling a brick pattern for forming a precast brick panel. The method includes conveying bricks in a row to a spacing station, spacing the bricks apart in a row at the spacing station according to a predetermined row pattern and to a predetermined row length by allowing the spacing between adjacent bricks to vary if required. The method then involves transferring the row of spaced bricks onto a generally planar support surface of a brick pattern assembly station. By this method, a plurality of rows of spaced bricks are assembled adjacent each other on the support surface of the brick pattern assembly station to form a brick pattern.

A method for assembling a brick pattern for forming a precast brick panel. The method includes conveying bricks in a row to a spacing station, spacing the bricks apart in a row at the spacing station according to a predetermined row pattern and to a predetermined row length by allowing the spacing between adjacent bricks to vary if required. The method then involves transferring the row of spaced bricks onto a generally planar support surface of a brick pattern assembly station. By this method, a plurality of rows of spaced bricks are assembled adjacent each other on the support surface of the brick pattern assembly station to form a brick pattern.

A self-contained truck-mounted brick laying machine can include a frame that can support packs or pallets of bricks placed on a platform. A transfer robot can pick up and move the brick(s). A carousel can be coaxial with a tower. The carousel can transfer the brick(s) via the tower to an articulated and/or telescoping boom. The bricks can be moved along the boom by, e.g., linearly moving shuttles, to reach a brick laying and adhesive applying head. The brick laying and adhesive applying head can mount to an element of the stick, about an axis which is disposed horizontally. The poise of the brick laying and adhesive applying head about the axis can be adjusted and can be set in use so that the base of a clevis of the robotic arm mounts about a horizontal axis, and the tracker component is disposed uppermost on the brick laying and adhesive applying head. The brick laying and adhesive applying head can apply adhesive to the brick and can have a robot that lays the brick. Vision and laser scanning and tracking systems can be provided to allow the measurement of as-built slabs, bricks, the monitoring and adjustment of the process and the monitoring of safety zones. The first, or any course of bricks can have the bricks pre machined by the router module so that the top of the course is level once laid.

A self-contained truck-mounted brick laying machine can include a frame that can support packs or pallets of bricks placed on a platform. A transfer robot can pick up and move the brick(s). A carousel can be coaxial with a tower. The carousel can transfer the brick(s) via the tower to an articulated and/or telescoping boom. The bricks can be moved along the boom by, e.g., linearly moving shuttles, to reach a brick laying and adhesive applying head. The brick laying and adhesive applying head can mount to an element of the stick, about an axis which is disposed horizontally. The poise of the brick laying and adhesive applying head about the axis can be adjusted and can be set in use so that the base of a clevis of the robotic arm mounts about a horizontal axis, and the tracker component is disposed uppermost on the brick laying and adhesive applying head. The brick laying and adhesive applying head can apply adhesive to the brick and can have a robot that lays the brick. Vision and laser scanning and tracking systems can be provided to allow the measurement of as-built slabs, bricks, the monitoring and adjustment of the process and the monitoring of safety zones. The first, or any course of bricks can have the bricks pre machined by the router module so that the top of the course is level once laid.

A robotic system having a movable gantry robot (10) for conducting construction operations. The gantry may have an expandable bridge (20) and articulated gantry support legs (34) as well as a support track system (60) holding a gantry robot (800) which may hold one or more implements and peripheral devices (806). The device can be moved by propulsion mechanisms, a controller, and one or more geo-positioned control devices to provide position information for the robotic gantry as it moves back and forth along a plurality of work sites (700). The robotic gantry is connected to a power supply system (236). The controller is automated, self-navigating, and activates, deactivates, and/or changes the operation of the propulsion mechanisms, and deploys, retracts, activates, deactivates, and/or changes the operation of one or more of the construction implements. The height of the frame may be adjusted by extending and rotating risers and booms to accommodate different building heights or sub-level heights at a worksite. A conveyor system is optimized for removing dirt from or delivering material to the robotic arm. This invention can be applied to automating construction jobs including surveying, land preparation, excavation, foundation, masonry, framing, and additive fabrication.