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Automation & Robotic

Assignment 1-Journal

(Automation in Constuction)

A development of next

generation intelligent

construction liftcar toolkit for

vertical material movementmanagement

Name : Mohamad Aliff Mohd Sahimi

ID : 7697


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A development of next generation intelligent construction liftcar toolkit for vertical

material movement management

Chang-Yeon Cho a,1, Soonwook Kwon c,, Tae-Hong Shin b,2, Sangyoon Chin c,3, Yea-Sang Kim c,3

a Korea Institute of Construction Technology, Goyang 411-712, South Koreab Samsung SDS., Seoul 135-918, South Koreac Dept. of Civil, Architectural, and Environmental System Engineering, Sungkyunkwan Univ., Suwon 400-746, South Korea

a b s t r a c ta r t i c l e i n f o

Article history:Accepted 3 May 2010

Available online xxxx

Keywords:

Construction lift

Material management

USN

RFID

Wireless sensing

Material movement

High-rise construction sites, especially those situated in spatially-constrained urban areas, have difficultiesin timely delivery of materials. IT-driven management techniques can be further benefited from state-of-the-

art devices such as Radio Frequency Identification (RFID) tags and Ubiquitous Sensor Networks (USN), which

have resulted in notable achievements in automated logistics management at the construction sites.

Based on those achievements, this research develops USN hardware toolkits for hoists, which aims to

automate the vertical material delivery by sensing the material information and routing it automatically to

the right place. The gathered information from the sensors can also be used for monitoring the overall status.

To support the system, a hoist-mountable intelligent toolkit was developed. Its feasibility test was conducted

by applying the implemented system to a test bed and then analyzing efficiency of the system and the

toolkit.

2010 Elsevier B.V. All rights reserved.

1. Introduction

Unlike other industries where single standard manufacturing

process can be applied to a batch of production items, each

construction project requires its own production process highly

customized to individual project characteristics. As a result, each

construction project has a unique, flexible logistics process for

procurement of materials [4]. Therefore, planning of a supply chain

management system should be flexible, which would accommodate

highly variable project environment, from large-scale urban renovation

to high-rise building construction [3].

In such environment, where only limited number of material

lifting equipments are available, careful planning for the operation

of the equipments is needed for efficient logistics management

in construction site [13,19]. According to the precedent re-

search [1,2,6], it was indicated that the efficiency of the lifting

equipments varies with regards to the building height, and that

planning of the material lifting affects the overall duration of the

construction; furthermore, increased building height would lead to

exponential increase of the information to be managed such as

scheduling and cost, let alone the increased material quantity.

Especially in construction sites in spatially-constrained urban

areas, planning and managing the logistics of the materials directlyaffect the construction schedule and the cost; if a problem breaks

out, it would trigger cascading problems in other parts in the

project which would result in production delays and cost overrun.

Many techniques such as Six Sigma, JIT (just-in-time production),

Lean Construction have been applied to the area in order to

improve its efficiency; however, the industry demands automated

system for the management tasks, which have progressed rather

slowly [1,2].

This paper describes the development of an intelligent lift car,

which is a part of the multi-year national research project in

development of the intelligent construction logistics system. The

system under development utilizes remote sensing and communi-

cation technologies such as RFID (Radio Frequency Identification)

and USN (Ubiquitous Sensor Network) to capture the information of

material movement and to manage it in an intelligent manner. A

toolkit (which consists of various sensors and wireless communi-

cation modules) has been developed to convert existing lift cars into

the intelligent ones easily. The new lift car is designed to increase

the efficiency of vertical transportation, which is crucial for

successful on-site logistics, and to improve information manage-

ment related to it. Several field tests were conducted to assess the

capability of the new lift car. Overall goal of the development effort

is to propose a new alternative for the next generation construction

sites where many parts of their jobs are automated and intelligently

controlled.

Fig. 1 illustrates overall procedure of our research work.

Automation in Construction xxx (2010) xxxxxx

Corresponding author. Tel.: +82 31 299 7578; fax: +82 31 290 7570.

E-mail address: [email protected] (S. Kwon).1 Tel.: +82 31 910 0284; fax: +82 31 910 0114.2 Tel.: +82 2 3429 2114.3 Tel.: +82 31 299 7578; fax: +82 31 290 7570.

AUTCON-01145; No of Pages 14

0926-5805/$ see front matter 2010 Elsevier B.V. All rights reserved.

doi:10.1016/j.autcon.2010.07.008

Contents lists available at ScienceDirect

Automation in Construction

j o u r n a l h o m e p a g e : w w w. e l s e v i e r. c o m / l o c a t e / a u t c o n

Please cite this article as: C.-Y. Cho, et al., A development of next generation intelligent construction liftcar toolkit for vertical materialmovement management, Automation in Construction (2010), doi:10.1016/j.autcon.2010.07.008
http://dx.doi.org/10.1016/j.autcon.2010.07.008http://dx.doi.org/10.1016/j.autcon.2010.07.008http://dx.doi.org/10.1016/j.autcon.2010.07.008mailto:[email protected]://dx.doi.org/10.1016/j.autcon.2010.07.008http://www.sciencedirect.com/science/journal/09265805http://dx.doi.org/10.1016/j.autcon.2010.07.008http://dx.doi.org/10.1016/j.autcon.2010.07.008http://www.sciencedirect.com/science/journal/09265805http://dx.doi.org/10.1016/j.autcon.2010.07.008mailto:[email protected]://dx.doi.org/10.1016/j.autcon.2010.07.008


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2. As-is construction supply chain management (CSCM)

2.1. Precedent researches in CSCM

This section reviews precedent researches in the construction

supply chain management area we surveyed, which can be summa-

rized as the followingparagraphs. An earlier version of this survey can

also be seen in [1,2]. According to our survey, those past researches

fall in one of the following categories:fi

rst, enhancement of thelogistics management including application of new management

theories; second, improvement of the material procurement; third

(the last), adoption of new technology.

For the third category (adoption of new technology), it was

observed that the barcode-based systems were being replaced with

RFID-based ones, and that development of the management system

also reflected the transition for instance, utilization of the wireless

communication and development of decision support models based

on the new technology. When we narrow the scope down to vertical

material movement (e.g., lift cars and cranes), the related researches

may fall into the following categories:finding optimal arrangement of

tower cranes [11,12], load distribution between the vertical move-

ment equipments (for tower cranes, lift cars, and both) (Jung, 2004;

[3,14]), and support system for the equipments [13,19].

In [1,2], efficiency of high-speed construction lifts was analyzed.

According to it, the time needed for single lift operation can be

calculated as below:

Time needed for a single lift=favg: lifting height m = lifting speed m =min

2 round trip g + extra time needed for loading; unloading; etc:

Cho also argued that reduction of the extra time would be the best

tactic for improving efficiency of the lifting operation, if the

mechanical performance was steady. It was also found that,

considering their importance, there were surprisingly few researches

on automated systems for monitoring movement of the construction

materials via the lifting equipments as a part of the construction

supply chain management.

2.2. Precedent researches using RFID/USN technologies in CSCM

Effi

cientmanagement of the supplychains for constructionmaterialsis becoming more important as large-scale, high-rise projects are being

common. Around the world, many research activities on this area are

currently going on; among them, various practical approaches utilizing

RFID/USN technology, which can prevent time consuming chores and

potential mistakes in information handling by automatingmany parts of

the CSCM process, have been introduced.

In this section, precedent researches on application of the RFID/USN

technology are reviewed.

Among the state-of-the-arts, [15] showed a practical approach in

engineered component tracking using RFID; in [16], a convergent

approach that combines RFID with GPS (Global Positioning System)

and wireless communication technology was proposed. Automated

detection of the material location is another key research theme:

[9,10,17,18] proposed computational models for localization of the

RFID-tagged materials stored in a stockyard; also, attempts to use

the tracking information for managerial operations such as produc-

tivity analysis [7] and for progress management [5,8] have been

made.

2.3. Concept of next generation vertical transportation (and logistics)

management

Our research described in this paper aims to develop a construc-

tion lift car toolkit-based on RFID/USN technology, to support vertical

Fig. 1. Research procedures.

2 C.-Y. Cho et al. / Automation in Construction xxx (2010) xxxxxx

http://dx.doi.org/10.1016/j.autcon.2010.07.008http://dx.doi.org/10.1016/j.autcon.2010.07.008


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movement of the construction materials and works depending on

them. The background researches of its development made by the

authors were the development of the intelligent CSCM process [5]

identification mechanism for inter-equipment material movement

[4], and efficiency analysis of various construction lift types [1,2].

In thecontext of our research, the term next generation intelligent

CSCM automation system refers to the CSCMenvironment envisioned

by the authors where RFID/USN technology is widely used for optimal

management of the supply chain in construction projects frommaterial factories to construction sites, especially for large-scale

projects such as high-rise buildings [4].

The system will monitor overall flow of the construction materials

from a production line to their destinations in a construction site and

will be able to track current location of each material in real-time.

Fig. 2 illustrates the concept of the vertical CSCM, which is the main

objective of this research.

The intelligent CSCM for vertical transportation of the construction

materials consists of the following parts: a lift car equipped with RFID

readers and necessary wireless communication functionality; an RFID

reader-equipped intelligent mover (IM) that will load/unload the

RFID-tagged materials to the lift car; a CSCM logistics management

server that will provide the destination and quantity information of

the transported material to the lift car; and a monitoring system

which is responsible for the tracking current status of the material in

real-time [1,2].

At the construction site, whether given material is delivered to the

right place in right time can be monitored in real-time via project

management information system (PMIS); also, work progress

compared to construction schedule can be determined from the

monitored information. These aspects allow confidence in construction

management as well as improved efficiency in CSCM.

In this paper, we would like to propose a prototype of the

intelligent construction lift, based on an easily-deployable toolkit

which provides RFID reading capability and necessary wireless

communication capability.

3. Next generation intelligent construction liftcar

toolkit architecture

3.1. Performance requirements for the toolkit

There are two categories for performance requirements of the new

construction lift car with respect to the intelligent CSCM context:

software requirements and hardware ones.

For the lift car hardware (especially for the CSCM support), it must

fulfill the following requirements:

First, the RFID/USN functionality should be portable so that the

functionality can be transferred to new hardware (such as an

elevator) when the lift car is no more needed and therefore to be

removed; a toolkit system which integrates the required function-

alities seems desirable for satisfying this requirement.

Second, the hardware should be weather-proof because construction

sites are inherently exposed to adverse weather conditions.

Third, for the communication capability, it mustsupportmid-to-long

range communication, for both wired and wireless one, in order to

contact with thelogisticsmanagement serverand other servers such

as PMIS.

Fig. 2. Concept of intelligent vertical CSCM.

3C.-Y. Cho et al. / Automation in Construction xxx (2010) xxxxxx



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Fig. 3. 3-Tier based system architecture of toolkit software.

Fig. 4. Information model of toolkit software.




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Fourth, it must provide short-range wireless communication capa-

bility also for communicating with other intelligent equipments (for

instance, an intelligent mover) and handheld devices such as PDA.

Fifth, it must befriendly to the fieldusersat the construction site in

terms of usability.

Sixth, it should provide backup power (e.g. batteries) in case the

fixed power service fails.

Seventh, there must exist RFID readers and antennas for

identification of RFID tags.

For the software embedded to the toolkit, its requirements can be

summarized as below:

First, it must allow its users to access the loading information via

touch screen display; also, if any event breaks out during the

process of loading, it must be able to display theevent in real-time.

Second, initial loading plans stored in the PMIS must be relayed to

the onboard computer in the toolkit so that the intelligent lift car

system can be operated as planned. This functional requirement

can be implemented using web service for the PMIS and its proxy

running on the toolkit's control computer.

Third, overall software must be configured as three-tier system

architecture so that plug-and-play concept of the toolkit can be

implemented easily.

Fourth, if something went wrong during the loading process,

details of the problem must be logged to the systemand notifiedto

the responsible personnel.

Fifth, end result of the loading process must be reported to the

logistics management server from the toolkit's control computer

via asynchronous web service.

3.2. Toolkit software design

In order to operate properly, the control computer (based on an

industrial PC) must be able to communicate with other systems such

as the logistics management server and the PMIS; the latter system

will have the actual plan of the material movement. As mentioned

above, the toolkit system's control software is configured to have the

Fig. 5. Illustration of the intelligent lift toolkit concept for elevator and intelligent lift.

Fig. 6. Setting up embedded control module.




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3-tier architecture as the configuration provides flexibility and

extensibility, which suit well for our toolkit-based approach (Fig. 3).

Fig. 4 shows the information items regarding the operation of the

intelligent lift. This information model diagram follows the UML

(Unified Modeling Language) notation, which illustrates the relation-

ships between the toolkit and other related systems regarding the

information exchange among them.

3.3. Toolkit hardware design

Fig.5 summarizes tasks theintelligentlift toolkit is supposed to do,

which is based on the hardware requirements listed earlier.

Figs. 6 and 7 show a prototype toolkit we designed for the tasks

sorted out in Fig. 5. Fig. 6 shows the design of the control module that

contains the embedded computer.

Because construction lifts typically have two doors one for entry

(loading) and the other for exit (unloading), two separate RFID

readers are used for each door. For the control computer, we used an

industrial PC with integrated touch screen display. The display is

ergonomically mounted at 120 cm from the floor deck for comfort of

the human operators.

To provide emergency power service in case main power service

fails, a lead-acid battery pack is installed with a power inverter to

provide AC power to the toolkit.

Fig. 7 shows the console-section design of the toolkit.

3.4. Toolkit software design

Fig. 8 shows a UML activity diagram of the information exchange

process during the intelligent lift operation. The PMIS provide the as-

planned loading information to the control PC of the intelligent lift car

via Web service; similarly, the logistics management server accepts the

result information from the control PC of the lift via Web service too. In

this manner, the planning information and the information of actual lift

operation can be managed in a single intelligent CSCM framework.

4. Manufacturing and test result analysis

4.1. Manufacturing and test plan

To evaluate the feasibility of our intelligent lift car toolkit, we built

a working prototype system and then conducted performance tests

against it. The following sub-sections describe the detail of the tests.

4.1.1. Manufacturing toolkit

Our prototype system consists of the toolkit hardware and its

control software. Table 1 lists the hardware specification of our

intelligent construction lift car toolkit.

Fig.9 shows thepicture of ourtoolkit apparatus anddescriptionof its

components. The entire toolkit is hosted in a single cabinet enclosure,

which also has two RFID readers and one battery pack inside.

4.1.2. Toolkit test plansWith the prototype toolkit, we have conducted three tests in total.

Table 2 gives a brief description of each test.

The first one was a pilot test for evaluating the performance of the

individual components. It evaluated the RFID readers (for their

identification ranges with various tag positions) and communication

modules including Zigbee and wireless internet over CDMA cellular

telephony network.

Fig. 7. Detailed design of the intelligent lift toolkit on console section.




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Thesecond test wasmade against the assembled toolkit prototype,

which comprised tests of eight RFID antennas for measuring

identification performance, tests of short-range data communication

between the intelligent equipments, tests of wireless internet services

using CDMA and Wibro modules, and tests of the backup battery

measuring its service time.

The third one was the field test of the toolkit installed to the lift

hardware with the system software we developed. To assess the real-

world performance of the prototype, the test evaluated functionality

of the system software and its interoperability with external systemssuch as the intelligent logistics server and the PMIS.

4.2. Toolkit performance tests

4.2.1. Pilot type test

The pilot test was conducted against the individual component of

the toolkit to see whether it met our functional requirements. It

comprised three sub-tests and each one is described as follows:

First, identification range and S/N ratio of the RFID antennas

Second, short-range communication test using Zigbee

Third, operation of the wireless communication module.

Fig. 10 illustrates test settings and various test conditions.

The result from the first test can be summarized as follows:

First, inside the construction lift car which was made of steel,

short-range communication using Zigbee within 5 m was stable

and noise-free.

Second, when a door of the lift car was closed, the RFID tags of the

materials outside the lift car were not identified; when the door

opened more than 1 m width, tags on the materials located within

5 m were able to be identified; when the door was fully open, the

range extended to 8 m.

Third, wireless internet access was attempted using a CDMA/Wibro

dual-mode modem for accessing external PMIS; 10 tests were

conducted, all of them were successful. Based on this result, a

Fig. 8. Process model of toolkit software.

Table 1

Specification of toolkit hardware.

Hardware Specification

1 CDMA/WiBro 900 Mhz/1.8 GHz

2 Zigbee 2.4 Ghz

3 RFID reader 900 Mhz

4 RFID tags Passive tag

5 Battery pack D.C 12 V

6 Industrial computer CPU Intel Pentium 4 2 Ghz

7 Touch screen monitor 12 in TFT LCD




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decisionwas made to usethe technology forcommunicating with the

PMIS.

4.2.2. Prototype test

The second test mainly evaluated the performance of the toolkit

hardware, which was developed based on the result from the earlier

pilot test.

The test evaluated the following items:

First, identification ratio with respect to various antenna types

Second, changes in identification ratio with varying locations of the

antennas

Third, changes in identification ratio with adjustment of the antenna

gain.

Fig. 11 illustrates the field condition for the test.

From the figure, dashed line around the material box and the

construction worker represent the entrance area to the lift car whichwasmade of steel meshes. Thetest used passive-type tags attached on

two different places top of the material box and side of it.

For the first test item (identification ratio over various antenna

types), which was conducted to determine the best antenna type for

our toolkit, the antennas were placed on sidewall of the lift car, which

was 130 cm above the floor deck and 30 cm away from the entrance

door horizontally. A receiver antenna and a transmitter one were

installed symmetrically to the sidewall so that they can face each

other.4

The test result was summarized in Fig. 12.

For the second test item (identification ratio over varying antenna

locations), we used the circular type antenna, as it performed better

than the linear type in the previous test. For this test, two antenna

pairs (each pair consisted of a receiver and a transmitter5) were first

placed at 2.65 m above the floor deck (highest location), and was

gradually lowered at 30 cm intervals as measurements were made for

each height setting. The test result is shown in Fig. 13.

Also, we tested different pair locations: symmetric locations of

RXTX pair versus asymmetric locations, which result is shown in

Fig. 14.

As a result, there was no observable difference in the identification

performance over different antenna heights; on the other hand,

location of the tag on the material box did cause the difference,

especially for top mounted vs. side mounted for right side vs. left

side, the latter performed better.

For the last item (identification performance over varying antenna

gains), we started from the maximum gain (zero value) and gradually

reduced the gain by 30 (the numeric value actually increased) until

the number reaches 255 (the minimum gain).

Fig. 15 shows the display screen of the control computer during

the test. Its test result showed that the antenna gain only marginally

affect the identification performance.

4.2.3. Field testFinally, we conducted the field test of our toolkit for evaluation of

its feasibility in the context of the intelligent CSCM environment, with

the system software developed for it.

The field test took place in the settings illustrated in Fig. 16.

The scenario for this test, for measuring feasibility of the toolkit for

vertical logistics management process under the intelligent CSCM

environment, is described as follows:

We first loaded four material boxes to the intelligent mover (IM),

which was developed in our earlier research [4]. Each box was

attached with a 900 Mhz passive RFID tag, and their information4 An RFID antenna can play two roles: a transmitter (TX) which sends off radio

signals to the RFID tag so that the tag can generate electrical power to send off its ID

information by induction; and a receiver (RX) which receives the radio signal from the

tag. These roles are interchangeable on a single antenna.

Fig. 9. Developing an intelligent lift toolkit.

Table 2

Test type definition.

Tests Test purpose

1 Pilot test Toolkit device performance test

2 Pro to type te st Toolkit perf or man ce t est

3 Field t est Too lkit +PMI S communication perf or mance t est

5 In Fig. 13, when the left-side antenna acted as RX, the right-side one would act as

TX, and vice versa. The RFID reader decided which one would be the RX.




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was picked up by the IM to be sent to the toolkit via the Zigbee

communication. The toolkit, which had already received the

shipping list from the intelligent logistics server, displayed the

destination floor on its touch screen and controlled the lift car to

move to the floor. When the lift car arrived, the IM moved out of

the lift car with the tagged box, and then the toolkit reports the

updated state, including the ID of the IM, the material, and the

floor and the materials were unloaded, to the intelligent logistics

server wirelessly.

Fig. 17 shows snapshots taken during the field test with

annotations.

The test result conformed well with our scenario: we conducted

three tests,and allof them exceeded ourperformancerequirements

for RFID identification ratio, successful communication ratio with the

intelligent movers, and successful communication ratio with the

intelligent logistics management server.

4.3. Test result analysis

From reviewing the tests we conducted, their test results can be

summarized as follows:

Thefirstpilot test wasintendedto seewhetherdevelopment of the

intelligent lift car system, was feasible; the test proved that

development of the system was feasible using available

components.

For the second test (against the prototype hardware), it was

intended to evaluate our design of the intelligent lift toolkit in

terms of its RFID identification performance, to see whether it was

deployable to actual construction sites where radio signal was easily

disrupted by various obstacles. The test result showed that the

hardware had enough performance to be used in such environment.

Finally, the third test sets up a scenario of the intelligent CSCM

process, and evaluated the system's performance within the

scenario. Also, the test evaluated whether the system could

interoperate with other equipments (e.g. the intelligent mover)

andremote systems such as theintelligentlogistics server. Thetest

result confirmed that the tested system performed well and couldbe deployed to the real-world construction sites.

5. Conclusion

In this paper, we discussed our research in development of the

intelligent construction lift toolkit, as part of our ongoing research in

thenext generation CSCM system. We built theprototype hardware of

the toolkit and its system software also. Using the prototype, we

evaluated its performance and verified its feasibility through multiple

performance tests. From these research activities, we have reached

the following conclusion:

First, the RFID technology can be applied to construction sites even

though they have adverse conditions in terms of radio signal

Fig. 10. Pilot test layout and test conditions.




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transmission due to various signal-blocking obstacles. This finding

allows automated recognition of the logistic items using the

technology.

Second, short-range data communication between the intelligent

equipments using Zigbee is feasible at the construction sites.

Third, application of long range data communication using

wireless internet technology such as CDMA/Wibro to construction

sites is also feasible (presumably in urban areas where its

infrastructure is well established) for communication with remote

systems such as theintelligentlogistics serverand thePMIS, which

allows real-time information exchange.

Fourth, our toolkit-based approach allows easy deployment of the

system to both construction lift cars and elevators.

Therefore, the intelligent vertical CSCM toolkit developed can be

transferred to elevators when they are installed to the building under

construction and they replace the lift cars, so the management system

can persist even after the lifts are removed.

In the future, as demonstrated with our prototype system, the

RFID/USN technology, which is technologically more superior than

conventional barcodes, will enable more advanced construction

project management once they are widely used in the CSCM area.

Fig. 12. Result of antenna type recognition test.

Fig. 11. Prototype test layout.




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Fig. 14. Result of RXTX test.

Fig. 13. Result of RX =TX test.




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Fig. 16. Field test conditions.

Fig. 15. RFID antenna detection range sensibility test.




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We hope this research will contribute to the transformation of theconstruction industry from labor-intensive to a more systematic and

information-centered one.

Acknowledgements

This work was supported by the KoreanInstitute of Construction &

Transportation Technology Evaluation and Planning (KICTEP) with

the program number of 06-Unified and Advanced Construction

Technology Program-D16.

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Fig. 17. Toolkit scenario field test.




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