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Designing the future of High-Altitude Construction
Traditional working at heights exposes workers to dangerous conditions, including falls, extreme heat, and toxic fumes.
Infinity X is a modular drone equipped with a robotic arm for high-altitude welding during maintenance.
Time
06.2024 - 09.2024
Type
Group project outside school
Role
Concept Development
Industrial Design
User Experience
UI/UX Design
Video Editing
04
ideation
05
Final Design
01
Design Background
02
Painpoints
01
Worker Safety
Welders working at heights face significant risks of falls, exposure to hazardous fumes, and potential injuries from handling multiple heavy equipment.
02
Labor Cost & Pollution
Needs for multiple workers to set up, operate, and supervise construction increases labor costs. Prolonged setup leads to extra construction pollution and noise.
03
Equipment Complexity
Setting up scaffolding or aerial work platforms for welding at height is time-consuming, physically demanding, and requires excessive manpower and equipment.
03
Design Statement
In order to enhance safety, efficiency and accessibility during the welding at height during construction, Infinity X minimize human involvement in potentially hazardous situations and reduce pollutions by integrating unmanned aerial vehicle (UAV) technology and AI assistance optimization.
Enhance Safety
Increase Efficiency
Minimize Interruption
Hazardous Working Environment
"1 in 250" construction workers face a fatal injury during welding.
"Falling on the ground" is the top industrial accident during construction. The dangers of working at heights and intense welding conditions increase the risk of accidents.
Component
CMF
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Infinity X welding system involves the coordination of two operators. The first operator, the Drone Pilot, focuses on flying the drone to the target location. The second operator, the Welder focuses on creating welding task. Meanwhile, the weld platform car sends the necessary gas, laser filler, and electrical power to the drone for welding.
Component
06
details
Gripping Module
This module helps to anchor the drone to a specific surface, providing a stable platform for subsequent welding.
Robotic Arm Module
This module is connected to the welding car and performs welding tasks after the drone flies to the destination.
5-axis laser welding arm
The robotic arm has 5-axis freedom and is capable of accomplishing high-precision welding requirements. The welding arm module includes an optional material nozzle and lazer head.
01
Robotic Arm Module
02
Propeller Arm
Four-bar mechanism
By incorporating a four-bar mechanism. The drone can adjust the height of the fly arm using only one linear stepper motor.
03
Gripping Module
Vacuum Mechanism
By incorporating a vacuum mechanism, the drone can attached to any flat surface. Its tripod feature makes sure the drone will not bob up and down.
Servo Motor 2
Control supporting arm rotate
Vacuum Generator
Create vacuum
Servo Motor 2
Control supporting arm rotate
04
Battery
Easy replacement
Two push buttons are placed on the side of the battery, helping Pilot readily to replace the battery.
Easy Replace
Push to unlock
Battery Indicator
Intuitive signal
05
Sensors
3D Scanning
There are cameras as well as sensors on the top, bottom, left and right sides to recognize the surroundings in all directions for timely obstacle avoidance as well as environmental scanning.
06
Inlet
Filter tube & gas tube
The filler tube delivers additional material to the weld area for improved strength and durability, while the shielding gas tube supplies an inert gas to protect the weld pool from atmospheric contamination and ensure a clean, high-quality weld.
shielding gas tube inlet
Filler inlet (optional)
07
Rotation
More freedom
The servo motors embedded in the drone ensure that the drone can rotate to adjust the optimal welding position when it is fixed in a particular position.
06
Welding Car Design
Knob
Handle
LED Indicator
USB Portal
Interlock
Emergency Button
Ventilation
Power/ Plugin
Output
Set up Welding Task
Welder can review the 3D model scanned by drone and create welding routine through the program on computer.
Adjust parameters on car
After creating the routine, Welder will setup the welding parameter on welding car based on the welding target. The task will be AI-optimized and sent to the drone.
