The present invention relates generally to building systems, and more specifically to systems and devices used in the construction of planar structural assemblies such as floors, roofs, and walls of commercial and residential buildings.
Construction of buildings require a number of tasks and areas of specialization. Electrical, plumbing, framing, drywall, painting, and numerous other professionals are required to successfully construct a residential or commercial structure. Much of a building's costs can be attributed to labor costs. Any reduction in labor costs can be highly beneficial.
One aspect of concrete roof and floor construction is the lateral joining of corrugated sheets of steel. This task has traditionally and still recently been performed by a laborer using a crimping tool to bind two adjacent corrugated sheets of steel. The worker may use other common methods depending on the application, such as bolts or screws or another type of binding device or technology. When crimping, the worker must perform multiple crimping functions with the crimping tool along the edge of the corrugated sheets of steel. Similarly, when a worker employs bolts, screws, or other fasteners, he must drill or otherwise affix the fastener to the joint in multiple locations. When such joints fail, they tend to fail dramatically, such as explosively.
Such procedures tend to be time consuming and generally inefficient. The worker could be performing other tasks or could be used for less time on the job.
It would be highly beneficial if the issues associated with joining corrugated steel or other corrugated metal pieces could be performed in a manner that overcomes the issues associated with using manual labor to perform such tasks.
The present design, in one embodiment, may include an apparatus comprising a rover vehicle comprising at least one movable arm configured to provide spot welding functionality, the rover vehicle comprising rover drive hardware configured to transport the rover vehicle over an upper corrugated sheet of metal, a crawler configured to travel under a lower corrugated sheet of metal beneath the upper corrugated sheet of metal, the crawler provided with crawler drive hardware and a movable electrode configured to be positioned at a lower position desired weld point, and a central power/data unit connected to the rover vehicle and crawler. The rover vehicle is configured to position one movable arm above the upper corrugated sheet of metal at an upper position desired weld point corresponding to the lower position desired weld point and effectuate a welding function.
According to another embodiment of the present design, there is provided a spot welding system comprising a rover vehicle comprising at least one movable arm and rover drive hardware configured to transport the rover vehicle over an upper corrugated sheet of metal, a crawler configured to travel under a lower corrugated sheet of metal beneath the upper corrugated sheet of metal, the crawler provided with crawler drive hardware and a movable electrode provided with electrode raising/lowering hardware configured to raise the movable electrode to a weld point, and a central power/data unit connected to the rover vehicle and crawler. The rover vehicle is configured to position one movable arm above the upper corrugated sheet of metal and effectuate a welding function proximate the weld point.
According to a further embodiment of the present design, there is provided a building construction spot welding apparatus comprising a rover comprising at least one movable arm and rover drive hardware configured to transport the rover vehicle over an upper corrugated sheet of metal, a crawler comprising crawler drive hardware configured to propel the crawler under a lower corrugated sheet of metal beneath the upper corrugated sheet of metal, the crawler provided a movable electrode provided with electrode raising/lowering hardware configured to raise the movable electrode toward the lower corrugated sheet of metal and toward a weld point, and a central power/data unit connected to the rover and crawler and configured to coordinate positioning between the rover, the crawler, and the weld point. The rover is configured to position one movable arm above the upper corrugated sheet of metal and effectuate a welding function proximate the weld point.
These and other advantages of the present invention will become apparent to those skilled in the art from the following detailed description of the invention and the accompanying drawings.
For a more complete understanding of the present disclosure, reference is now made to the following figures, wherein like reference numbers refer to similar items throughout the figures:
The exemplification set out herein illustrates particular embodiments, and such exemplification is not intended to be construed as limiting in any manner.
The following description and the drawings illustrate specific embodiments sufficiently to enable those skilled in the art to practice the system and method described. Other embodiments may incorporate structural, logical, process and other changes. Examples merely typify possible variations. Individual components and functions are generally optional unless explicitly required, and the sequence of operations may vary. Portions and features of some embodiments may be included in or substituted for those of others.
In general, the present invention is broadly directed to a system that travels along corrugated metal sheets, such as corrugated steel sheets, and performs spot welding at appropriate joints using a series of robotic or movable arms, a drive system that may include treads to facilitate movement over the corrugated sheets, and a crawler device generally located beneath the corrugated metal sheets. The device may be directed to a location and a number of robotic arms, such as four, may be positioned at appropriate locations relative to the corrugated metal seam and may spot-weld the sheets together using the known position of the crawler. In one aspect, the crawler and the device may be connected to a central power source and/or computing device such that the crawler operates below the corrugated metal in concert with the device operating above the corrugated metal.
In this embodiment, supports 408a, 408b, 408c, and 408d are provided, together with cross pieces 408e, 408f, 408g, and 408h. Four six degree of freedom (6-DOF) robotic arms 409a, 409b, 409c, and 409d are provided in this embodiment, but any number of such robotic arms or similar spot welding movable devices may be provided. In this view, crawler 405 is moving in one direction beneath a lower sheet of corrugated metal 411 while upper corrugated metal sheet 402 is located thereon with openings or channels oriented perpendicular to the openings or channels of the lower sheet of corrugated metal 411. In this manner, a connection can be formed to enable spot welding. The crawler assists in positioning the spot welding joint as will be described.
Spot welding is generally understood to employ copper alloy electrodes to be positioned on both sides of a metal joint. Current is applied and the applied current heats the “spot” and causes the metal to melt and form a spot weld button created between the two sheets. In the configuration of
The function of central rover controller 406 is to control the four 6-DOF arms and the drive system such as the four treads shown in
Note that based on the position of the crawler 405 and the location of the grooves and size of the grooves on the lower corrugated metal sheet 411, the system, such as central rover controller 406, may position 6-DOF arms 409a-d and the tips of such in position to facilitate a spot weld, such as on a known groove in the upper corrugated metal sheet and a known protrusion in the upper corrugated sheet. In other words, positional information of the rover 401 and components thereof as well as crawler 405 and the corrugated metal sheets are employed and desired positions determined as the rover 401 progresses and performs spot welds.
Movement may general be in a linear manner, however, the drive system may cause the rover 401 to rotate, such as by applying forward motion to one side and reverse motion to the opposite.
The process of spot welding is generally known, and collar 706, weld element 707, and tip 708 may be constructed in accordance with known spot welding designs and may include electronics and welding materials, and line 710 provides commands and power to weld element 707 and tip 708 as well as any other necessary components in 6-DOF arm 409d. Similar components are provided with each 6-DOF arm in this embodiment. As noted, spot welding employs a copper alloy, provided in or with the 6-DOF arm and tip includes an electrode. The system, such as central rover controller 406, may apply current at an appropriate time and may effectuate the weld. Such weld arms are generally used in the automotive industry, though not always in the precise 6-DOF arm arrangement shown.
Below point 803, the representation is generally split into rover functions on the left and crawler functions on the right, with common functions in the center. Point 801 calls for the rover to be connected to a central power/data unit, while point 807 calls for the crawler to be connected to the central power/data unit. At point 805, the rover maneuvers to a predetermined location within a dry-fit assembly of unwelded panels, while point 806 calls for the location sensors of the rover to communicate the position of the rover and the state of the rover's 6-axis arms to the crawler via the power/data tethers and the central power/data unit. Point 808 calls for the crawler to follow the rover in the groove or tunnel created by corrugations of the lowest panel. Point 809 calls for the crawler to receive the rover location via the power/data tether. At point 810, the rover and crawler may arrive at the welding location. At point 811, the rover may maneuver the 6-DOF arm above the crawler. Note that points “01” and “02” represent connections to lines in
From
At point 820, the system seam welds all overlapping points between panels using the appropriate 6-DOF arm(s), and at point 821 form work may be broken down and removed.
While the representations of
The apparatus hierarchy for interaction of the superior rover and return path crawler include the superior rover (SR) movement governing the movement of all other movable and controlled components of the system. Each of the return path crawlers (RPC), including one or more such RPCs, move in accordance with the movement of the 6-DOF arm that they are assigned to at the time. As the 6-DOF arm can travel much faster than an RPC and may interact with multiple RPCs, each RPC may travel in advance of the 6-DOF arm, arriving at the next weld point in an orientation ready to effectuate a weld. As the SR has freedom to rotate 180 degrees, it may reassign 6-DOF arms to different RPCs confined to their respective corrugation tunnels. When a 6-DOF arm is lowered into position above an RPC, that RPC then raises its electrode jack against the roof of its corrugation tunnel.
Certain finished panel performance factors govern apparatus choreography. For example, with respect to weld density, spot weld concentration typically does not exceed approximately or exactly two welds per square inch. Thicker material or material with various corrugation profiles have differing weld periods and different overall masses and impact the weld density specified. The controller or control unit may assess and account for such issues. The orientation of the corrugations of successive layers of the sheet metal may vary depending on dimensions of the span. For example, layers with an angular offset of 90 degrees may be ideally suited for a square deck area. By contrast, a long rectangular deck area may have ridges of the corrugation oriented to run the short length of the area, with an offset of less than or different from 90 degrees. Larger spans typically require additional layers of sheet metal for added strength. Control of the various components require this information, i.e. angular orientation of the openings and/or travel path of the RPCs, which may be sensed if sensing is available or may be provided by an operator or otherwise.
Again, in operation, the RPC position is known, and once in an advantageous weld position, the SR may be repositioned and/or the appropriate 6-DOF arm located above the RPC and a weld sequence initiated. 6-DOF arm movement may be in any appropriate manner, such as by rotating the arm and components of the arm, and/or laterally or vertically or otherwise linearly moving the elements of the arm into position.
In
Also note that while a single crawler is provided in the embodiments shown herein, multiple crawlers may be employed and the design is not so limited. Note also that while two layers of corrugated metal sheets are contemplated, the present design may be employed to weld more than two layers together as long as the crawler or crawlers can fit within the various corrugated channels of one lower level.
The present design, in one embodiment, may include an apparatus comprising a rover vehicle comprising at least one movable arm configured to provide spot welding functionality, the rover vehicle comprising rover drive hardware configured to transport the rover vehicle over an upper corrugated sheet of metal, a crawler configured to travel under a lower corrugated sheet of metal beneath the upper corrugated sheet of metal, the crawler provided with crawler drive hardware and a movable electrode configured to be positioned at a lower position desired weld point, and a central power/data unit connected to the rover vehicle and crawler. The rover vehicle is configured to position one movable arm above the upper corrugated sheet of metal at an upper position desired weld point corresponding to the lower position desired weld point and effectuate a welding function.
According to another embodiment of the present design, there is provided a spot welding system comprising a rover vehicle comprising at least one movable arm and rover drive hardware configured to transport the rover vehicle over an upper corrugated sheet of metal, a crawler configured to travel under a lower corrugated sheet of metal beneath the upper corrugated sheet of metal, the crawler provided with crawler drive hardware and a movable electrode provided with electrode raising/lowering hardware configured to raise the movable electrode to a weld point, and a central power/data unit connected to the rover vehicle and crawler. The rover vehicle is configured to position one movable arm above the upper corrugated sheet of metal and effectuate a welding function proximate the weld point.
According to a further embodiment of the present design, there is provided a building construction spot welding apparatus comprising a rover comprising at least one movable arm and rover drive hardware configured to transport the rover vehicle over an upper corrugated sheet of metal, a crawler comprising crawler drive hardware configured to propel the crawler under a lower corrugated sheet of metal beneath the upper corrugated sheet of metal, the crawler provided a movable electrode provided with electrode raising/lowering hardware configured to raise the movable electrode toward the lower corrugated sheet of metal and toward a weld point, and a central power/data unit connected to the rover and crawler and configured to coordinate positioning between the rover, the crawler, and the weld point. The rover is configured to position one movable arm above the upper corrugated sheet of metal and effectuate a welding function proximate the weld point.
The foregoing description of specific embodiments reveals the general nature of the disclosure sufficiently that others can, by applying current knowledge, readily modify and/or adapt the system and method for various applications without departing from the general concept. Therefore, such adaptations and modifications are within the meaning and range of equivalents of the disclosed embodiments. The phraseology or terminology employed herein is for the purpose of description and not of limitation.