Patent Application
20190032338
The present invention generally relates to roof shingle removal and installation, but more particularly to an automatic roof shingle removal and installation system.
It is well known that the removal and installation of roof shingles is a repetitive and hazardous task. Before installing new roof shingles, the removal of the existing roof shingles is required. Currently, various systems and methods for roof shingle removal exist. Some systems include prying devices that require extensive manual labor to operate. Other systems include machinery mounted to a truck that require the home to have clear access free of trees, porches, and other obstructions that would prevent a truck from driving the perimeter of the home. Other systems include guide systems for the debris that is onerous to install. Other automated systems include machinery that allow the debris to slide down the roof as it is removed potentially falling on vegetation or the ground requiring manual cleanup.
Likewise, systems and methods for roof shingle installation also exist. Some systems include manually operated installation tools that improve efficiency while still being dangerous and labor intensive. The roof shingle systems of the prior art have multiple deficiencies including (a) inability to overhang the roof's rake edge to complete a full row of material installation; (b) mechanical fastener mounting unable to adjust nail placement complying with different building codes and shingle manufacturer's installation instructions; (c) mounting of guide rails requiring extensive set-up time for the operator; (d) larger apparatus sizes are unable to install roof material closer to the peak of a roof; (e) inability to flip shingles as they are separated from the bundle as shingle manufacturers package bundles so every other shingle if facing a different direction to avoid the tar from sticking together destroying the new roof shingles; (f) inability to precisely stagger the seams according to different shingle manufacturer installation specification; and (g) mechanical fastener mountings prevents systems from leaving one nail unfastened around chimneys, valleys, vents, and other obstructions so the roofer can finish the metal flashing.
Further, existing systems focus on either removing the old material or new roof shingle installation, requiring roofers to purchase additional equipment for every stage of the process. Consequently, there is a need to provide an automatic roof shingle removal and installation system that is faster, and requires less manual labor than existing systems.
An automatic roof shingle installation system is provided, comprising: a roof shingle installation apparatus having a compartment configured to hold a bundle of shingles and a rotatable shingle peel member configured to separate a single shingle from the bundle of shingles and flip the single shingle.
In one embodiment, the roof shingle installation apparatus further comprises a shingle position member and at least one fastening member, wherein the shingle position member is configured to position the single shingle into position for fastening and the at least one fastening member is configured to fasten the single shingle to a roof, wherein the at least one fastening member is movable enabling precise locational control of fasteners corresponding to any shingle manufacture installation specification and building code requirement. In one embodiment, the shingle installation apparatus further comprises a cutting device configured to cut the single shingle at any angle and/or length necessary for installation.
In one embodiment, a navigational apparatus configured to traverse the roof is provided, the navigational apparatus comprising at least one movable drill assembly including at least one independently actuated drill having a fastening means preventing the navigational apparatus from slipping off the roof, and a mounting element configured to attach the roof shingle installation apparatus to the navigational apparatus such that the shingle installation apparatus is enabled to traverse the roof via the navigational apparatus. In another embodiment, the navigational apparatus further comprises a structural body housing a plurality of components including a microcontroller, a gyroscope, a wireless communication means, and an accelerometer, wherein the wireless communication means is used to communicate the navigational apparatus with a mobile device enabling an operator to safety control and monitor the system. In yet another embodiment, the navigational apparatus further comprises proximity sensors configured to detect an edge of the roof and a plurality of wheels, wherein the at least one movable drill assembly, the proximity sensors, and the position of the plurality of wheels enable the navigational apparatus with the attached roof shingle installation apparatus to overhang an edge of the roof allowing for the installation of shingles on an entire row of the roof increasing surface area coverage. In one embodiment, the navigational apparatus can traverse a hip roof and avoid obstructions without the use of guide rails, pulleys, or armatures. In one embodiment, the at least one movable drill assembly is a movable horizontal drill assembly and a movable vertical drill assembly, wherein the movable drill assemblies each include two independently actuated drills. In another embodiment, the gyroscope is configured to detect an angle of the navigational apparatus and the microcontroller can fasten one of the independently actuated drills of the vertical drill assembly, and push the navigational apparatus back into a level horizontal position such that the navigational apparatus is auto-leveling ensuring the navigational apparatus travels in straight lines.
In another aspect of the invention, an automatic roof shingle removal system is provided, comprising: a roof shingle removal apparatus including a prying member configured to pry existing shingles from a roof, wherein the existing shingles pried from the roof are stored in a debris bin. In one embodiment, the debris bin can be raised and/or lowered such that the existing shingles may be emptied in a precise location.
In another embodiment, a navigational apparatus configured to traverse the roof is provided, the navigational apparatus comprising at least one movable drill assembly including at least one independently actuated drill having a fastening means preventing the navigational apparatus from slipping off the roof, and a mounting element configured to attach the roof shingle removal apparatus to the navigational apparatus such that the shingle removal apparatus is enabled to traverse the roof via the navigational apparatus.
In one embodiment, the navigational apparatus further comprises a structural body housing a plurality of components including a microcontroller, a gyroscope, a wireless communication means, and an accelerometer, wherein the wireless communication means is used to communicate the navigational apparatus with a mobile device enabling an operator to safety control and monitor the system. In another embodiment, the navigational apparatus further comprises proximity sensors configured to detect an edge of the roof and a plurality of wheels, wherein the at least one movable drill assembly, the proximity sensors, and the position of the plurality of wheels enable the navigational apparatus with the attached roof shingle removal apparatus to overhang an edge of the roof allowing for the removal of shingles on the edge covering greater surface area. In yet another embodiment, the roof shingle removal apparatus further comprises least one cutting element configured to cut the existing shingles from the roof and wherein the microcontroller enables the navigational apparatus with the attached roof shingle removal apparatus to located a position of a debris collection container on a ground surface adjacent to the edge of the roof such that the existing shingles stored in the debris bin can be deposited directly into the debris collection container; and wherein the roof shingle removal apparatus further comprises a debris shoot positioned at a top portion of the debris bin allowing the deposited existing shingles to clear gutters when deposited into the debris collection container.
In yet another aspect of the invention a system is provided, comprising: a navigational apparatus configured to traverse a roof, the navigational apparatus comprising a connection element, a movable horizontal drill assembly, and a movable vertical drill assembly, wherein the drill assemblies include independently actuated drills each having a fastening means preventing the navigational apparatus from slipping off the roof; a roof shingle removal apparatus configured to remove existing roof shingles, wherein the roof shingle removal apparatus is attached to the navigational apparatus via the connection element; and a roof shingle installation apparatus configured to install new roof shingles, wherein the roof shingle installation apparatus is attached to the navigational apparatus via the connection element.
In one embodiment, an auto-retractable lifeline safety harness is provided, wherein the harness is configured to attach to the navigational apparatus as a safety measure in case the navigational apparatus becomes detached from the roof unexpectedly. In one embodiment, roof shingle installation apparatus comprises a compartment configured to hold a bundle of shingles and a rotatable shingle peel member configured separate a single shingle from the bundle of shingles to rotate the single shingle 360 degrees. In one embodiment, the roof shingle installation apparatus further comprises a shingle position member, wherein the shingle position member is configured to travel along an x-axis and the rotatable shingle peel member is configured to travel along a y-axis. In another embodiment, the roof shingle installation apparatus further comprises at least one fastening member configured travel along a z-axis, wherein the at least one fastening member is configured to fasten the single shingle to the roof, and wherein the movement of the navigational apparatus and the at least one nailers enables precise locational control of fasteners corresponding to any shingle manufacturer installation specification and building code requirement.
One object of the present invention is to re-use the same navigation machinery for both roof removal and new shingle installation, allowing the operator to leverage the investment in the system for the entire roofing process.
Another object of the present invention is to work with multiple shingle manufacturer specifications, building codes, and existing packaging of material, requiring the system to flip shingles, cut the shingles to any length, and place nails in precise locations.
Yet another object of the present invention is to increase surface area coverage by removing and placing shingles up to the edge and peak of the roof.
One object of the present invention is to allow the operator to specify the location to dump the debris from the roof removal, allowing the operator to put all contents into a dumpster or debris slide avoiding plant destruction and manual cleanup.
Another object of the present invention is to enable the operator to safely control and monitor the system from a mobile device.
Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out their invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the general principles of the present invention have been defined herein to specifically provide an automatic roof shingle removal and installation system.
In one embodiment, the horizontal body member includes a first slot 17A running the length of the horizontal body member, wherein the first slot allows a horizontal drill assembly 12 to travel along a first threaded rod 17. Likewise, in one embodiment, each of the pair of vertical body members include a second slot 16A running the length of each of the pair of vertical body members, wherein the second slot allows a vertical drill assembly 13 to travel along a second threaded rod 16.
In operation, best seen in
In one embodiment, each drill assembly comprises at least one drill 26 having a plurality of tension springs 27, wherein the plurality of tension springs force the drill towards the roof during operation. The at least one drill also comprises a threaded plate 33 for receiving a lag screw 31. It is a particular advantage of the present invention, that the lag screws are configured to be fastened into the roof deck preventing the navigation apparatus from slipping off the incline of the roof. The threaded plate allows the lag screw to rotate up or down preventing the plurality of tension springs from constantly applying pressure into roof, and specifically the roof sheathing. In one embodiment, limit switches 40 are provided to stop further drilling when the lag screw is already fastened into the roof deck.
As previously mentioned, the navigational apparatus is configured accept the roof shingle removal or installation apparatus during use. Either apparatus is attached via connection mounting bracket 14 located on a bridge member 13A, which is part of the structural body between each drill of the vertical drill. A plurality of wheels 15 are position on the underside of the bridge member, the horizontal body member, and the pair of vertical body members. The position of the plurality of wheels enables the navigational apparatus to overhang the edge of the roof allowing the removal and installation of shingles on the edge of the roof. In one embodiment, the navigational apparatus includes proximity sensors 91 located at the distal ends of the pair of vertical body members, wherein the proximity sensors detect the edges of the roof.
In one embodiment, a power supply 34 is provided to convert the supplied AC power to DC power as well known in the art. In one embodiment, an integrated circuit 35 is provided, wherein the integrated circuit includes several electronical components including but not limited to a microcontroller, a gyroscope, a wireless communication means, and an accelerometer. It is a particular advantage of the present invention that the navigational apparatus includes auto-leveling capabilities ensuring the navigational apparatus travels in straight lines. For instance, the angle of the navigational apparatus is detected via the gyroscope, wherein the microcontroller can fasten one of the independently actuated vertical drill assemblies, and push the navigational apparatus back into a level horizontal position utilizing the second threaded rod.
The roof shingle installation apparatus comprises a shingle position bar 46 consisting of a pair of vertical body members 46A and a horizontal body member 46B. The shingle position bar rolls along a structural body 95 via needle bearing wheels 32A. Specifically, the shingle position bar is attached to lead screws 57 that travel along threaded rods 55 which rotate on bearings 19B. In one embodiment, the linear motion of the shingle position bar is powered by motor 62, and the power is transferred to each threaded rod via shingle position bar rod 53 and miter gears 54. The linear motion is a horizontal motion along an x-axis corresponding to the structural body.
In one embodiment, the roof shingle installation apparatus further comprises a shingle peel bar 51 that is configured to be moved vertically along a y-axis corresponding to the pair of vertical body members. The shingle peel bar is attached to lead screws 57A which travel along vertical threaded rods 63, which are rotated on bearings 19C. In one embodiment, the vertical motion is powered by motor 66 coupled to shaft 65 via coupler 21A, and transferred to both vertical threaded rods 63 with miter gear 58. It is a particular advantage of the present invention, that the shingle peel bar is configured to rotate 360 degrees around axis 64 via motor 70 which actuates worm gear 76. This rotation is critical as the 360 degree rotation is used to flip shingles to face opposite directions. Since it is well known in the art, that roof material manufacturers package shingle bundles with every other shingle facing a different direction to prevent applied tar from sticking together and ruining the shingles. In one embodiment, a mounting bracket 74 is provided to attach the shingle peel bar axis, wherein the mounting bracket is configured to hold a plurality of rollers 69. A separating edge 51B provided on the bottom side of the shingle peel bar, separates a shingle from the bundle of shingles 89 (best seen in
In one embodiment, the cutting device is a nibbler as well known in the art, wherein the nibbler is used to precisely cut shingles. It is a particular advantage of the present invention, that the cutting device can cut a shingle at any length or any angle by precisely moving the cutting device along axis 64 while the shingle is moved through via rollers 69 at a different axis. For instance, angle cut shingles are needed for valleys as well known in the art. Likewise, shingle manufacture installation guides require different lengths to be cut to stagger the seams of the roof, as well known in the art.
During operation, the shingle peel bar is configured to pick up, flip, and move a single shingle from the bundle of shingles into position for fastening on the roof. In one embodiment, the bundle of shingles is held in tray 47. Each new shingle is fastened to the roof via pneumatic nailer guns 41. In one embodiment, two independently actuated pneumatic nailer guns are provided. Each pneumatic nailer gun comprises air cylinders 43 and a solenoid 45 configured to actuate the air cylinders to move the nailer down to the roof deck during operation. An air hose connector 44 provided on the apparatus is configured to be attached to the pneumatic hose (5B;
It is also a particular advantage of the present invention that the weight of each component of the system and each apparatus can be attached to the roof and is also light enough to use a standard boom lift often used to lift shingles onto the roof as well known in the art. Further, in some instances the bundles of shingles may be manually carried up a ladder as well known in the art. Other methods, such as cranes and pulley may also be used. A bundle of shingles weighs approximately 70 pounds. The total weight of the present invention is at most 200 pounds, wherein each apparatus of the system is 60 pounds or less, thus users can use the standard boom lift or other methods known in the art to raise the bundle of shingles on the roof for each component of the system as well.
It is also a particular advantage of the present invention that the navigational apparatus can traverse a variety of roof types such as a hip roof and avoids a variety of obstructions including but not limited to chimneys, skylights, and dormers without the use of guide rails, pulleys, or armatures.
Although the invention has been described in considerable detail in language specific to structural features and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention. For instance, although a pneumatic system is disclosed an electric system may be provided without departing from the spirit and scope of the invention. Another variation may include a single integral unit comprising each apparatus described. However, as previously mentioned limiting the weight of the system is critical since the system needs to be lifted onto a roof during use. Therefore, the aforementioned design feature wherein each component is a separate component is ideal. Then, the components may be assembled on the roof prior to operation.
It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.
In addition, reference to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) are not used to show a serial or numerical limitation but instead are used to distinguish or identify the various members of the group
This application is a divisional of application Ser. No. 15/659,630 filed Jul. 26, 2017.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15659630 | Jul 2017 | US |
| Child | 15917234 | US |
