Patent Application
20080263995
The present invention relates to a method and apparatus for constructing a building, which is automated to a large degree.
Conventional frame building construction relies on labour intensive manual work. Once an appropriate foundation is laid, workmen install joists and flooring, erect wall frames, add wall sheathing on both the exterior and interior surfaces, add roof trusses and roof sheathing, all as is well-known in the art. Furthermore, plumbing and wiring require drilling holes in framing members and joists to route the wires and pipes to appropriate locations. A large crew of skilled tradesmen are required for such assembly.
There is a need in the art for automated methods of construction, which employ an apparatus for such automated methods of construction.
In one aspect, the invention may comprise a method of constructing a building, comprising the steps of:
In one embodiment, the engagement means comprises a plurality of pins which engage a plurality of grooves, wherein the pins and grooves are disposed on mutually complementary surfaces of the trailing edge of the panel and the leading edge of the next panel. In one embodiment, the mutually complementary surfaces may be inclined planes.
In one embodiment, the horizontal force is applied in a continuous manner. In another embodiment, the horizontal force is applied in an intermittent manner. Preferably, the horizontal force is interrupted as each successive joist reaches a predetermined distance from the installation position, where the next joist is positioned, thereby allowing strong and stable attachment of the upper and lower panels to each joist. In one embodiment, the horizontal force is a pull force, applied to the first joist. In another embodiment, the horizontal force is a push force, which may be applied to each successive joist.
In another aspect, the invention comprises an apparatus for automating building construction comprising:
The invention will now be described by way of an exemplary embodiment with reference to the accompanying simplified, diagrammatic, not-to-scale drawings.
The present invention provides for an automated method of construction, and an apparatus for implementing such methods. When describing the present invention, all terms not defined herein have their common art-recognized meanings. To the extent that the following description is of a specific embodiment or a particular use of the invention, it is intended to be illustrative only, and not limiting of the claimed invention. The following description is intended to cover all alternatives, modifications and equivalents that are included in the spirit and scope of the invention, as defined in the appended claims.
In the following description, the terms “horizontal” and “vertical” are used with their normal meanings. However, one skilled in the art will recognize that embodiments of the invention may vary in this regard. What is important is the relative orientation of the various components and forces described below. The term “front” shall refer to the elongate side of the framing machine (1) from which the structural member (10) being assembled is produced. The “rear” side is opposite the front side.
In one embodiment, the automated construction method of the present invention and the framing machine (1) produces a planar structural member (10) in a process analogous to an extrusion of building material. A horizontal force is applied to elements used to assemble the structural member, as it is being assembled. In one embodiment, a pull force is used to elongate the structural member, rather than a push force. In another embodiment, a push force may be used. The produced structural member (10) may be used in an exterior wall, interior wall, a floor, an upper floor or a roof.
The framing machine (1) may be suspended from construction cranes, or otherwise positioned with suitable means. In one embodiment, the framing machine may be trailer mounted. The trailer (not shown) may have levelling means and be self powered, so as to be maneuverable. Each wheel at each corner may be powered and pivotable so that the trailer and framing machine may be precisely positioned as required. Preferably, each wheel has a height adjustment capability which permits precise levelling of the entire framing machine (1).
The planar structural member (10) comprises a plurality of vertical joists or trusses (12), which separate and support planar sheathing on at least one of, and preferably both top (14) and bottom (16) as may be generally seen in
The joists and joist bay (24) are a length which preferably is a multiple of a board or panel length. If standard 4′×8′ panels are used, the joists may be 8, 16 or 24 feet. Longer joists are of course possible and result in structural members (10) extending beyond the boards such that a portion of the joist is uncovered by boards.
Above the joist feeder (22) is an upper panel feeder (30) comprising a panel bay (32) for holding a plurality of vertically stacked horizontal panels, which form the upper sheathing (14). The upper panel feeder (30) may rely on gravity to feed the panels downwards, or the upper panel feed may be mechanized in any suitable fashion. An upper panel actuator (34) pushes the bottommost upper panel towards the front of the apparatus. The upper panel actuator (34) comprises a small ram and a push attachment (35) which is generally the thickness of a single panel or less. Each upper panel and each lower panel has a leading edge which faces the front (F) of the framing machine, and a trailing edge which faces the rear (R) of the framing machine. The upper panels may rest directly on the joist array, in which case a moveable support may be introduced from the rear of the upper panel bay as the joist array is moved outwards.
Below the joist feeder (22) is a lower panel feeder (40), comprising a panel bay (42) for holding a plurality of vertically stacked horizontal panels (16). The lower panel feeder includes a lift mechanism (44) comprising support beams connected to hydraulic rams (46). Alternative lift mechanisms may include a scissors platform or other mechanical means for forcing the lower panel array upwards. A lower panel actuator (48) comprises a small ram and a push attachment (49) which is generally the thickness of a single panel or less.
The upper (34) and lower (48) panel actuators are only required to position the first upper panel and the first lower panel. Thereafter, the panels have engagement means as described below to continuously feed panels to be assembled into the structural member.
In one embodiment, both lower panel bay (32) and upper panel bay (42) may have an adjustable length by means of loading clamps (41), the operation of which is shown in
As used herein, a “joist” shall mean any elongate secondary structural member such as a beam, stud, joist, truss, or an engineered wood member. The panels may be conventional construction boards such as plywood, oriented strand board or other panels.
The joist feeder (22), upper panel feeder (30) and the lower panel feeder (40) may be formed by frame members (28) of adequate structural strength to provide the rigidity the apparatus needs to support its contents and be transported. In one embodiment, the frame members may comprise metal beams. Positioning hooks (29) on the largely metal frame permit manipulation of the frame and positioning of the entire apparatus.
The structural member (10) is formed by sequentially attaching upper and lower panels to the joists in appropriate distance intervals. The forward edge (11) of the structural member (10) is defined by the first joist (13). The first joist (13) is pushed out by the joist feeder until the first joist hits a first barrier (52) which is mounted to a barrier arm (51) at each end of the joist feeder (22). The first barrier (52) is aligned with the installation position, as shown in
In the installation position, an upper and a lower panel are pushed outward, or otherwise positioned, until they are aligned with the installation position and are attached to the first joist (13). The first joist (13) is attached by suitable means to a cable, actuated by a winch or other suitable means, which pulls the first joist (13). The cable may be attached to the first joist (13) by a flange hook (53) as is shown in
The first joist is supported vertically by a support structure (50) which extends out the distance of the structural member to be constructed. The support structure (50) may support the edges of the joist/panel combination, or may provide direct support underneath the structural member (10) and should preferably be a smooth, low friction surface. The support structure is aligned with the bottom of the framing machine (1) such that the structural member moves onto the support structure as it is being formed.
As shown in
In one embodiment, each panel defines engagement means on its leading and trailing edges. The trailing edge (90) of a first panel (92) and the leading edge (91) of the next panel (93) form mutually complementary surfaces (94), such as matching inclined planes, with interlocking engagement means. In one embodiment, the interlocking engagement means may comprise a plurality of pins (95) and grooves (96). On one surface, an array of pins (95) is provided. On the matching surface, an array of grooves (96) which are positioned to engage the pins is provided. As well, each panel may comprise a combination of both pins and grooves, so long as each edge of a panel is complementary to the adjacent edge of another panel. Preferably the pins are not longer than the height of the panel itself, so as not to protrude upon assembly.
As the trailing edge (90) of a panel is pulled away from the next panel, which exists above the panel in the upper panel feeder, or below it in the lower panel feeder, the matching inclined planes (94) engage, and the pins (95) engage the grooves (96), as shown in
As the first panel is pulled away from the array, the engagement means thus attaches the next panel to the first panel in the horizontal plane.
When the first joist (13) has reached a predetermined distance away from the installation position, the second joist is attached to the upper and lower panels. The predetermined distance may be measured by means of a second barrier (54) on the barrier arm (51). Obviously, the spacing between the first and second barriers (52, 54) determines the spacing between joists in the structural member. The second barrier is on a track allowing it to move to and from the first barrier, providing the ability to vary the distance between joists. The second barrier may take the form of an optical sensor which determines when the first joist has reached an appropriate spacing distance. As shown in
The width of the upper and lower panels is preferably equal to a multiple of the distance between two successive joists. For example, if standard 4′×8′ panels are used, then the distance between joists may be 16″ or 24″. Accordingly, the seam comprising overlapping complementary surfaces between panels (14) will align with a joist, and both adjacent panels may be attached to the same joist, as is shown in
In a preferred embodiment, an adhesive is also used between adjacent panels to further enhance the rigidity of the structural member (10). The adhesive may be applied to the mutually complementary surfaces by means of appropriately placed adhesive dispensers, as is shown in
The process of assembly may be continuous, partially continuous or intermittent. If continuous, the pull speed must be sufficiently slow so as to allow fastening of the successive panels without misalignment. In an intermittent process, a sensor such as an optical sensor may measure the length of board that has passed signaling when the next joist must be connected and momentarily stop the pull force until fastening is complete. The intermittent process may allow the use of screw fasteners, adhesives or spot welding, which may require more time to complete the fastening process.
The assembly process is preferably automated by means of a microprocessor operating a suitable algorithm or reading a software file that dictates the exact spacing of the joists in the structural member. The control system (100) shown in
In one embodiment, the joist support rails (25) prevent the lower panels from extending right to the edge of a joist. Therefore, if it is desired that the panels extend past the joists or be flush with the joists, the joists cannot be supported within the joist bay from the underside. In this embodiment, the joists are supported internally by an internal support member (57) which extends horizontally through the joist bay and impales the joists, thereby suspending them within the joist bay, as is shown in
Once a completed structural member (10) has been formed and rests on the support (50), another structural member may be formed on top of the existing structural member by moving the framing machine upwards. In this case, smooth strips of a material may be placed on top of the existing structural member, to reduce friction between the two members as the second member is being formed.
In one embodiment, the framing machine (1) includes a system for inserting mechanical pipes and wires in the structural member (10) as it is being assembled. The lines and wires may include plumbing, HVAC ducts, electrical wires or any other duct, tube or wire-like material that is normally placed within walls or floors of a conventional building. In one embodiment, the wires and pipes (60) are coiled on spools (62) or in boxes at the rear of the apparatus and each is fed through holes or openings in the arrayed joists and connected to the first joist. Thus, as the first joist is pulled in the assembly process, the wires and pipes will be pulled along and threaded through all of the joists in the structural member. In an alternative embodiment, the line materials are placed on the structural member largely in front of the first joist, threaded through the arrayed joists and connected to the last joist, or an anchor point on or near the apparatus. The line materials are then moved along with the first joist as it is pulled, thus accomplishing the same result. In an alternative embodiment, the line materials are placed on the front side of the framing machine, threaded through the arrayed joists and connected to the last joist, or an anchor point on the apparatus thus accomplishing the same result. In another alternative embodiment the line materials are placed on the rear of the machine and threaded through the arrayed joists but not connected to the structural member, the line materials are laid in the structural member as it is being produced by an active mechanism such as opposed wheels.
In one embodiment, illustrated in
In one embodiment, shown in
Alternatively, rolled barrier material may be provided at the rear of the framing machine and placed between the joists and the lower panels or the upper panels. The barrier material is then fastened to the joists and the panels as the structural member is assembled and moved out of the machine.
In an alternative embodiment, portions of the structural member (10) may be pre-assembled and stacked in the framing machine (1) as is shown in
The first Z-assembly (101) may then be pulled or pushed outward with the horizontal force previously described. Each panel in the Z-assembly comprises the mutually complementary surfaces (94), such as matching inclined planes, with interlocking engagement means, described above. In one embodiment, the interlocking engagement means may comprise a plurality of pins (95) and grooves (96). As the first Z-assembly is moved outwards, the trailing edge of the upper panel of the first Z-assembly will engage the leading edge of the upper panel of the next Z-assembly, and at the same time, the trailing edge of the lower panel of the first Z-assembly will engage the leading edge of the lower panel of the next Z-assembly. Therefore, a horizontal force on the first Z-assembly will continue to pull the chain of Z-assemblies outwards. The process may then continue and the structural member may be formed in the manner described above.
This application claims priority of U.S. Provisional Patent Application 60/914,563 filed on Apr. 27, 2007 entitled “Automated Construction System With Interlocking Panels”, the contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60914563 | Apr 2007 | US |
