Method of joining wooden members

Description

The present invention relates to apparatus and methods for forming wooden frames and the like and particularly relates to apparatus and methods for forming discrete connector plates of the type having integrally extending teeth from coiled strips of sheet metal and embedding the teeth of the plates into the opposite sides of joints of prepositioned wooden members to fabricate a frame or the like.
It is currently common practice to utilize connector plates of the type having integrally struck teeth to form the joints between the various members comprising a wooden frame. For example, connector plates of various sizes and widths, depending upon the structural requirements of the frames, are commonly embedded in the joints of wooden roof trusses and truss-type floor joists. An example of such connector plates is disclosed in U.S. Pat. No. 2,877,520 of common assignee herewith. To accomplish the foregoing, it is typical industry practice for a frame fabricator to preposition precut wooden members of a jig table in the form of the desired frame and spot precut connector plates on opposite sides of the frame joints. The fabricators then utilize various methods for embedding or pressing the teeth of the connector plates into the opposite sides of the joints to form the completed frame. An example of a fabricating system of this type is illustrated in U.S. Pat. No. 3,602,237 of common assignee herewith. In that patent, precut connector plates are spotted on a jig table on the opposite sides of the joints formed by the prepositioned wooden members, the jig table being then stepped through a press position whereby the joints are successively located between the platens of the press and the connector plates carried thereby embedded into the joints. In U.S. Pat. No. 3,603,244, also of common assignee herewith, the press is moved along the jig table and is automatically stopped at each joint position to embed the connector plates.
Currently, connector plates are provided frame fabricators in various sizes either cut exactly to the length required or in discrete sizes constituting a multiple of the required lengths. The fabricator cuts these latter longer connector plates to form connector plates of the required lengths. These connector plates, hereinafter sometimes referred to as bar stock, are very often packed by a supplier in one of two ways. The bar stock is either tumble-packed, i.e., the connector plates being randomly disposed in a box, or packed in teeth-to-teeth relation, i.e., paired connector plates in teeth-to-teeth facing relation. It will be appreciated that teeth-to-teeth packaging requires extensive manual labor to orient the discrete plates in proper position for such packaging. Tumble packing also requires a degree of labor to complete the packaging process and has the additional disadvantage of low density packaging. Furthermore, the fabricator, upon receiving the packages of connector plates, must unpack the plates and individually spot the plates at their proper locations as previously discussed. Where the connector plates are provided in multiples of the desired lengths, the fabricator must, of course, additionally cut these long connector plates to the desired lengths prior to spotting. Thus, the current practices in providing connector plates to a frame fabricator and his handling of such plates up to final securement thereof in a frame requires considerable labor, time and expense.
It has therefore been found desirable to provide novel apparatus and methods for forming connector plates of this type and to provide novel apparatus and methods for fabricating wooden frames and the like. Generally, the present invention provides coils of sheet metal strips, each of which strips is fed through a die set where teeth are struck integrally therefrom to form a strip of connector stock which stock is thereafter fed into the path of movement of a press head whereupon the stock is cut to form a connector plate of the required length and located on one side of the joint of a frame for embedment of its teeth into such joint. The following description of a frame fabricating machine relates to an embodiment of the present invention particularly useful for fabricating wooden pallets. It will be appreciated, however, that the methods and apparatus as described herein can be utilized in the fabrication of a wide variety of wooden frames and the like including but not limited to trusses, wall panels and truss-like floor joists. With respect to the specific embodiment of the present invention disclosed herein, there is provided generally a machine for fabricating pallets adapted to carry coils of sheet metal in strip form and which coils constitute a magazine from which such coil strips are fed to the machine. The machine is provided with die sets for striking teeth from the coils of sheet metal and feed assemblies which unwind the coils for feeding the strips through the die sets advancing the strip with the teeth struck therefrom discrete distances toward press-cut-off assemblies, each advance corresponding in distance to the length of the connector plates desired. At each press-cut-off assembly, a discrete length of connector strip is cut from the connector stock and the teeth of the connector plate thus formed is embedded into a side of the joint of prepositioned wooden members forming a part of the frame being fabricated.
More particularly, the frame machine disclosed herein includes a conveyor mounting upper and lower press head assemblies on C-frames on opposite sides of the conveyor. The upper and lower legs of each C-frame each carry a die set for punching teeth in the sheet metal strip as it is advanced toward the press head assemblies. Each press head assembly includes a platen, upper and lower platens being located on opposite sides of the frame members on the conveyor and movable toward and away from one another. Stops are carried by the upper press head assemblies for aligning the side chords or rails in a pressing position. Stops are also carried by the conveyor between the press-cut-off assemblies on opposite sides of the conveyor for aligning the webs in respective pressing positions. Clamps carried by the conveyor squeeze the chords against the ends of the webs. Each press platen carries a cutting blade to cut a selected length of connector plate from the stock fed to such press head assembly by the feed assembly. The upper and lower press platens carry the connector plates for embedment into the joint during the final portions of their movement toward one another.
Generally, to complete a frame, the chords and webs are disposed on the conveyor with the chord ends butting the stops carried by the upper press head assemblies and the first web butting the stops carried by the conveyor between the press-cut-off assemblies. Upon actuation, the die sets operate to punch teeth in the strips from the coils while simultaneously the upper and lower press platens move toward one another cutting predetermined lengths of connector plates from the portions of the connector stock beyond the die set and which portions carry the integrally struck teeth. The upper and lower platens carry the plates for embedment into the opposite sides of the joints during the final portions of their strokes. Upon retraction of the platens, the stops for the chords and web are also retracted. In this manner, the partially completed frame comprised of two chords and a first web may be advanced along the conveyor. Particularly, this three-part pallet is advanced by a power roller until the first web butts stops carried by the conveyor spaced a distance from the press head corresponding to the length of the frame whereby the trailing ends of the chords are located between the press platens. The second web is moved forwardly with the three-part frame until it butts the web stops in line with the press heads whereby the second web is located between the chords and in a pressing position. As the partially completed frame is advanced and after the first die stamping, stock cutting and pressing cycle, the feed mechanism advances the connector stock toward the press head assemblies to locate predetermined lengths thereof between the press platens. Once the second web and the chords are positioned between the press head assemblies, die sets are again actuated to punch teeth from the strips and, simultaneously, the press platens are actuated to cut connector plates from the stock and embed the teeth thereof into the opposite sides of the joint on opposite sides of the conveyor.
It will be appreciated that significant material handling problems are encountered with respect to connector plates particularly in view of the projecting teeth thereof and that such problems are solved by the present invention in the provision of coiled strips of sheet metal stock fed to a machine which punches the teeth in the sheet metal strips substantially simultaneously with the cutting of stock in which teeth have been previously formed and embedding the connector plates thus formed into the joints of a frame. Features of the present machine include the provision of comb-like guides of tines on the fixed cutting blades and in the feed mechanism whereby the machine is vertually jam-proof. The teeth of the connector stock, after the stock is advanced from the die set, engage in the grooves between the tines and guide surfaces on the opposite sides of the stock from the teeth. Thus, only longitudinal feeding movement of the stock is permitted with the stock being held against lateral movement by the tines and against movement withdrawing the teeth from between the tines by the guide surfaces.
Another novel feature resides in maintaining the stock substantially free of vertical movement, i.e. perpendicular it its longitudinal extent, during stamping operations. This avoids excess withdrawal of the strip from the coil on one side of the die set while enabling the stock strip with the punched teeth on the other side of the die set to maintain its longitudinal position thereby assisting to feed accurate predetermined lengths of the strip into the path of movement of each press head. To accomplish this, both the die punch and die are withdrawn from the strip after the punching operation thereby enabling longitudinal movement of the strip with its punched teeth relative to the die set without vertical displacement of the strip.
A further novel feature of the present invention resides in the feed mechanism which not only insures that the connector plates are cut to the desired predetermined length but also that the connector stock is cut at a longitudinal location between its teeth. From U.S. Pat. No. 2,877,520, it will be noted that connector plates are provided with teeth arranged in both longitudinal and transversely extending rows. It is important that a transverse row of teeth not be aligned at the juncture of the fixed and movable cutting blades so that the teeth per se are not sheared or weakened by the shearing process. It will be appreciated that connector plates do not have identical tooth-to-tooth spacing in a longitudinal direction. That is to say, an inherent characteristic of a connector plate of this type is that the teeth are spaced from their theoretical longitudinal positions progressively further distances in proportion to the length of the stock from the stamping operation. Also, the feed assembly cannot repeatedly advance identical lengths of stock and some error is often introduced here. Accordingly, such cumulative errors in the longitudinal location of the transverse rows of teeth would result in locating one such row of teeth between the fixed and movable cutting blades. In the machine hereof, however, the connector strip is always cut at a location such that the cutting blades shear through the connector plate per se without engaging any teeth. To accomplish this, a pilot pin is inserted between a pair of transverse rows of teeth prior to each feed to longitudinally adjust the stock relative to the cutting blades to ensure that the teeth are not aligned therewith. The cut is thus made substantially medially between next adjacent transversely extending rows of teeth. Consequently, the teeth on the opposite sides of the cut remain effective in both the connector plate just cut from the stock and the nest connector plate to be cut from the stock.
A further important feature of the present invention resides in the provision of a fixed cutting blade having a comb-like surface, i.e., tines. The teeth of the connector stock are received between the tines and the ends of the tines support the plate during the shearing operation. The tines thus provide the reaction force for the cutting operation.
A still further important feature of the present invention resides in accurately locating the plate in the joint. It will be appreciated that the plate when cut from the stock tends to first bend away from the movable cutting platen and then jumps from the platen and stock when fully sheared therefrom. To prevent this, the present invention provides a device for holding the plate when it is sheared from the stock. The device includes a dovetail notch or groove carried on the movable cutting blade and a corresponding dovetail projection carried on the fixed blade. When the plate is cut from the stock, a dovetail notch is formed along its trailing edge leaving a dovetail projection on the leading edge of the stock. The dovetail notch on the cut plate engages with the dovetail projection of the fixed cutting blade whereby the plate is held against lateral and longitudinal movement relative to the machine. That is, the plate is held by the dovetail until just prior to embedment of the teeth into the joint. To prevent the forward end of the plate from bending away from the moving platen when cut, a magnet is located on the platen to hold the plate thereaginst. Spring-biased plungers or spring clips may also be utilized on the platens to provide lateral support for the connector plate. These locators ensure that after each plate is cut from the connector stock, it is carried to the joint and located precisely relative thereto.
Accordingly, it is a primary object of the present invention to provide novel and improved apparatus and methods for fabrication wooden frames and the like.
It is another object of the present invention to provide novel and improved apparatus and methods for substantially simultaneously stamping teeth in a sheet metal strip, cutting a connector plate from a portion of the strip previously punched and embedding the teeth of the connector plates into the joint of a wooden frame.
It is a related object of the present invention to provide novel and improved apparatus and methods for applying connector plates of the type having integrally struck teeth on the opposite sides of wooden frames and the like.

These and further objects and advantages of the present invention will become more apparent upon reference to the following specification, appended claims and drawings, wherein:
FIG. 1 is a fragmentary plan view of a wooden frame fabricating maching contructed in accordance with the present invention;
FIGS. 2 and 3 are end and side elevational views thereof respectively;
FIG. 4 is an enlarged fragmentary cross sectional view of die set, feed and press assemblies forming a part of the fabricating machine illustrated in FIG. 1;
FIG. 5 is an enlarged plan view thereof;
FIGS. 6, 7 and 8 are enlarged fragmentary cross sectional views thereof taken about on lines 5--6, 7--7, and 8--8, respectively, in FIG. 4;
FIG. 9 is a fragmentary enlarged cross sectional view illustrating the manner in which connector stock is cut to form a connector plate;
FIG. 9a is an enlarged fragmentary cross sectional view taken about on line 9a--9a in FIG. 4;
FIG. 9b is a plan view of a joint formed by the plate P hereof;
FIG. 10 is an enlarged vertical cross sectional view of a die set for use in forming the teeth in the sheet metal stock taken generally about on line 10--10 in FIG. 5;
FIG. 11 is a cross sectional view thereof taken generally about on line 11--11 in FIG. 10;
FIG. 12 is a schematic illustration of a pneumatic circuit for use with the fabricating machine hereof;
FIG. 13 is a schematic illustration of a hydraulic circuit for use with the fabricating machine hereof;
FIG. 14 is a schematic illustration of an electrical circuit for use with the fabricating machine hereof;
FIGS. 15a - 15e are schematic representations of the manner of fabricating a pallet utilizing the fabricating machine hereof.

Referring new to the drawings, particularly FIGS. 1-3, there is illustrated a wooden frame fabricating machine constructed in accordance with the present invention and generally indicated 10. Machine 10 generally includes a conveyor 12, a pair of press assemblies 14 on opposite sides of conveyor 12, and a power roller assembly 16 for moving partially completed frames along conveyor 12. With the exeption of various elements of power roller assembly 16, the fabricating machine hereof is symmetrical on opposite sides of the centerline of the conveyor and it will be appreciated that a description of the various assemblages on one side of the conveyor centerline is also a description of the like assemblages on the other side of the conveyor centerline.
Conveyor 12 includes a pair each of table and roller conveyor sections 18 and 20 respectively on opposite sides of press assemblies 14, each pair of sections 18 and 20 being symmetrical on opposite sides of the conveyor centerline. Table sections 18 are located on the wooden material input side of the press assemblies 14 and each includes an elongated support base 22 having upstanding supports 24 at opposite ends and a table 26 carried by supports 24. Diagonal braces 27 are provided by supports 24 and table 26. A pair of lumber guide angles 28 are mounted along the outside edges of each of tables 18, the upstanding angles 29 facing inwardly toward the conveyor centerline. Guide angles 28 are secured to tables 18 by releasable clamps 30 whereby angles 28 are movable in a transverse direction to vary the spacing between transversely opposed angles in accordance with the width of the wooden frame being fabricated. Mounted at the ends of tables 18 adjacent press assemblies 14 are pneumatically actuated lumber clamps 32 each commprised of an air actuated spring return cylinder 34 and a clamp head 36. The lumber clamps 32 are similarly adjustably mounted on tables 18 for movement in a transverse direction whereby they can be positioned in accordance with the width of the frame undergoing fabrication.
Each roller conveyor section 20 on the output side of press assemblies 14 includes pairs of upright conveyor supports 38 at its opposite ends mounting at their upper ends transversely spaced rails 40. Rollers 42 are mounted between rails 40 at spaced longitudinal positions therealong. A pair of plates 44 and 46 overlie each roller section 20 at spaced longitudinal positions and each plate carries an adjustable lumber guide angle 28' similar to the previously described angles 28. Plates 44 in addition, mount lumber clamps 32' directly adjacent press assemblies 14, clamps 32' being identical to the previously described lumber clamps 32.
Power roller assembly 16 includes a transversely extending shaft 50 which overlies roller conveyor sections 20 and mounts a pair of cushion rolls 52 for engagement with the upper faces of the lumber carried by roller conveyor sections 20. Opposite ends of shaft 50 are mounted in suitable bearings 54 carried on pressure arms 56 located on the outboard sides of conveyor sections 20. The opposite ends of each pressure arm 56 is pivotally secured to a bracket 58 mounted on roller conveyor section 20. On one side of the conveyor, a second pressure arm 60 is pivotally mounted to a bracket 62 also mounted on roller conveyor section 20 for pivotable movement about a like axis as pressure arm 56. Pressure arm 60 carries a hydraulic motor 64, the output shaft of which is coupled to the shaft 50 by means of a keyed flexible coupling 66. A spring 68 is secured between each roller conveyor section 20 and the pressure arm carried thereby. Rollers 52 are thus biased in a downward direction for engagement along the lumber disposed on roller conveyor 20.
As noted previously, press assemblies 14 are located between each longitudinally aligned pair of table and roller conveyor sections 18 and 20 respectively. Each press assembly 14 comprises generally a C-frame 70 carrying upper and lower press platens 72 and 74, upper and lower supports 76 and 78 (FIG. 2) for the reels carrying coiled elongated sheet metal strips (hereinafter sometimes referred to as stock 8), a feed assembly generally indicated 80 (See FIG. 4), a pair of die sets 81, and a stock cutting assembly 82 (See FIG. 4). Each C-frame 70 is mounted for movement toward and away from one another whereby wooden frames having various selected widths can be fabricated by the machine hereof. Particularly, C-frames 70 are each mounted on a support assembly generally indicated 83 comprised of a transversely extending rectangular structural tubing 84 mounting plates 86 along its top surface at its opposite ends. Tubing 84 is supported by a base comprised of vertically inclined uprights 92. Each C-frame 70 comprises a pair of longitudinally spaced C-frame plates 88, the lower ends of which mount clamps 90 which releasably clamp about the opposite edges of support plates 86. Thus, the C-frames 70 are mounted for adjustable sliding movement toward and away from one another.
For reasons which will become clear, a center support assembly 96 is carried by the central portion of tubing 84. Particularly, the center support assembly includes a table 98 located transversely between the C-frames 70 and at an elevation corresponding to the elevation of conveyor sections 18 and 20. Table 98 is supported by uprights 100 secured at their lower ends to tubing 84. Table 98 carries on opposite sides thereof air cylinder actuated web stop assemblies 102 including pop-up shafts 103 for reasons which will become apparent from the ensuing description. Conveyor sections 20 also carrying along their inboard sides air cylinder actuated web stop assemblies 105 including pop-up shafts 107.
The reel supports comprise a pair of tranversely spaced arms 103, 105 secured at one end to the outer edges of C-frame plates 88 and have slots 104 at their opposite ends for receiving outwardly projecting pins 106 carried by reel arbors 108. The reels include a hub 109 and side plates 110, the hub 109 having a larger diameter than arbors 108. In this manner, the reel is offset downwardly with its center of gravity below its axis of rotation to provide a pendulum effect thereby preventing any tendency of the metal strip when its free end is fixed to rotate the reel and become unwound.
Referring now to FIG. 4, the coiled metal strips S are advanced from the upper and lower reels through die sets 81 by the feed assembly 80 and toward the press platens 72 and 74. The feed assembly 80 is carried by a guide plate 118 which is secured to the C-frame plates 88 directly by screws, not shown. The feed assembly 80 as well as the pair of dies sets 81 are also supported by slide rods 114 carried on the outer sides of plates 88. The rods 114 extend from opposite sides of guide plate 118 through bearings 119 on the outer sides of the C-frame plates 88. Thus, feed assembly 80 and die sets 81 can be unscrewed from the C-frame plates 88 and retracted along bearings 119 and remain supported by rods 114 whereby total disconnection of the feed assembly and die sets from the press assembly, for example to obtain access to their various parts, is not necessary.
Referring now to FIGS. 10 and 11 in conjunction with FIG. 4, upper and lower die sets 81U and 81L respectively are provided each press assembly 14 with both sets being supported by a pair of spaced side plates 85 connected at their forward ends to guide plate 118 and straddling adjacent their opposite ends vertically spaced upper and lower die shoes 87U and 87L. Upper and lower die sets 81U and 81L include respective die punch actuating cylinders 89U and 89L secured to the corresponding die shoes, the pistons of which cylinders respectively carry die punch plates 91U and 91L. Each punch plate includes a plurality of longitudinally and tranversely spaced punches 93 for striking a plurality of teeth from the metal strip as it is advanced through each die set in a manner set forth below. Also carried by the punch plates 91U and 91L are strippers 95 biased away from the punch plates by springs 97 carried by retaining pins 99 slidably secured to the respective punch plates.
Upper and lower dies 101U and 101L are carried by respective upper and lower die support plates 105U and 105L, the interior and opposed faces 107 of which are laterally inclined to receive therebetween the wedge 109 carried by the piston of a die actuating cylinder 111. Cylinder 111 is carried by a support bracket 113 secured to the side of one of plates 85. Upper and lower guide rods 115U and 115L respectively are threaded at one end to the corresponding die support plate and are slidably received in suitable bores in the corresponding upper and lower die shoes 87U and 87L. Springs 117 lie in cavities formed in the upper and lower guide shoes and bias the die support plates into following engagement with the inclined surfaces of the wedge 109 whereby the dies 101U and 101L are withdrawn or stripped from the metal strips upon retraction of the wedge in a manner set forth below. The end of the wedge 109 carries an actuating element 121 for a switch 376 for actuating the same when the wedge is fully extended into position for forming the teeth in the metal strip. Also, as illustrated in FIG. 10, a pin 121 is carried by the upper die punch plate 91U for actuating a switch 373 when the die punch plate is fully extended and the teeth are fully formed in the metal strip.
Referring now to the feed assembly, guide 80 is slotted along its upper and lower sides to receive the flanges of upper and lower channel shaped stock guide tables 120 and 122, respectively. Stock guide tables 120 and 122 extend toward the peripheries of the upper and lower stock reels and the upper and lower exits of die sets 81 and straddle, on upper and lower sides, a stock feed cylinder 124 which is threadedly connected at its forward end in guide 118. Feed cylinder 124 carries a piston shaft 126 which is connected at its forward end to a stock clamp and feed assembly generally indicated 128. Referring particularly to FIG. 4, a pair of horizontal guides 127 and 129 are carried by die set shoes 87U and 87L to guide the metal strips from the coils into the upper and lower die sets respectively. A pair of brackets 130 are mounted on opposite sides of guides 127 and 129 and are slotted at their opposite ends at 132. Upper and lower entrance guide rollers 134 and 136 are disposed between the opposed ends of brackets 30 and pins 138 carrying rollers 134 and 136 are received in the slots 132. Springs 140 are coupled between pins 138 whereby rollers 134 and 136 are biased in a direction towards their respective guides to maintain the strips between the respective rollers and tables.
Referring to FIG. 6, channel-shaped guide plates 142 and 144 are connected to the upper and lower sides of guide 118 whereby guide plates 142 and 144 form upper and lower passages 146 and 148 for receiving the stock with the teeth formed therein enroute to the press platens. Each channel shaped stock guide plate 142 and 144 has a transversely extending bore 150 through one side thereof and through which is received a pilot pin 152. The outer end of each pilot pin 152 is carried by a cylinder plate 154 which, in turn, is mounted on the piston shaft of a pilot cylinder 156. The pilot cylinder 156 is secured to the respective stock guides by cylinder brackets 158. Accordingly, it will be appreciated that extension and retraction of the pistons within the pilot cylinders 156 causes the pilot pins 152 to retract and extend into the respective guide spaces 146 and 148 for purposes as will become apparent from the ensuring description.
Referring now particularly to FIGS. 4 and 7, the feed clamp assembly 128 includes a slide block 160 mounted on a pair of slide rods 162 for sliding movement between the full and dash lines position illustrated in FIG. 4. The rods 162 are secured at one end to guide 118. Slide block 160 is recessed along its upper and lower sides as indicated at 164 and 166 respectively and upper and lower jaws 168 and 170 are secured to slide block 160 on its opposite sides within the respective recesses 164 and 166. The upper and lower surfaces of jaws 168 and 170 respectively are grooved in a longitudinal direction to form transversely spaced tines indicated 172 and 174, respectively. That is to say, such surfaces form a longitudinally extending comb-like surface which receive the teeth of the connector stock as it is fed forwardly to the press platens. In this manner, the connector stock is maintained in a predetermined lateral location. Mounted on opposite sides of slide 160 are upper and lower cylinder brackets 176 and 178 respectively. Each bracket is counterbored to threadedly receive the ends of upper and lower clamping cylinders 180 and 182 respectively. Cylinders 180 and 182 mount grippers 184 and 186 respectively on the ends of their respective piston shafts. It will be appreciated that extension of the grippers toward the opposite jaws clamps the connector stock between the tines of the jaws and the grippers. As illustrated in FIG. 4, the entrance ends of jaws 168 and 170 are flared to facilitate entry of the stock through the clamp assembly 128. The forward end of slide block 160 carries an alignment block 184 which is stepped at its forward end for alignment between the spaced upper and lower cutoff blade mounting blocks 186 and 188 respectively which form part of the press assembly.
Referring to FIGS. 4 and 8, blocks 186 and 188 are mounted between C-frame plates 88 and mount upper and lower plates 190 and 192 respectively, which in turn, mount the fixed upper and lower cutting blades 194 and 196. Plates 190 and 192 are suitably secured on opposite sides to the under and upper sides of the upper and lower mounting blocks 186 and 188 respectively and are spaced therefrom to define respective upper and lower stock passages 198 and 200. Plates 190 and 192 as well as mounting blocks 186 and 188 are enlarged adjacent the entrance apertures to passages 198 and 200 to facilitate entry of the stock. Cutting blades 194 and 196 are each provided with a plurality of transversely spaced tines indicated 201 defining grooves 202 therebetween for receiving the teeth of the stock. That is to say, the blade 194 carries upwardly directed tines for receiving the downwardly directed teeth of the stock passing through passage 198, the plate portion of the stock passing between the edges of tines 201 and the lower face of block 186. Likewise, the tines 201 of the fixed lower blade 196 project downwardly whereby the grooves 202 receive the upwardly projecting teeth of stock passing through passage 200 between plate 192 and mounting block 188, the plate portion of the stock being received between the edges of tines 201 and the upper face of block 188. The forward edges of tines 201 on each of the fixed lower and upper blades 194 and 196 form cutting edges whereby discrete upper and lower plates may be sheared from the stock by the press platens in a manner to be discussed. That is, the edges of the comb-like tines 201 on the fixed cutting blades form fixed reaction surfaces for cooperation with movable cutting blades whereby connector plates are cut from the stock S.
Referring to FIGS. 4 and 8, the upper block 186 on each press assembly carries an air actuated chord stop cylinder 197. The piston shaft 199 is extensible into and retractable from the space defined between upper and lower plates 190 and 192 whereby, when extended, shaft 199 serves as a stop for locating each chord of the frame. Note that shafts 199 and 103 of the web stop assemblies lie in transverse alignment one with the other.
Upper and lower press cylinder plates 210 and 212 respectively extend between the C-frame plates 88 and mount upper and lower press cylinders 214 and 216 respectively. Cylinders 214 and 216 are threaded into bearing plates and the piston shafts respectively carry the upper and lower press platens 72 and 74. Platens 72 and 74 carry respective cutting blades 218 and 220 for cooperation with the fixed upper and lower blades 194 and 196 to shear the connector strips S to the selected lengths for use in the frame being fabricated. It will be appreciated that simultaneous extension of the pistons of the press cylinders 214 and 216 moves the platens 72 and 74 toward one another whereby the ends of the stock are cut by the moving and fixed blades with the cut connector plates being carried by the platens for embedding the teeth thereof into the opposite sides of the frame parts between the press heads in a manner to be described.
For maintaining accurate plate location after they have been cut from the strips, the cutting blades 218 and 220 of the upper and lower press platens each have a dovetail groove 211 centrally along its cutting edge and rear face, i.e., the face thereof in opposition to the corresponding fixed blade 194 or 196. The fixed blades 194 and 196 each carry an outwardly projecting dovetail shaped tongue 213 along its cutting edge and forward face for registration with the corresponding dovetail groove 211. Accordingly, when the press platens move toward one another, the grooves 211 and tongues 213 cooperate to cut a dovetail shaped groove 217 (FIG. 9B) along the rear end of the plate P which is being cut from the stock, leaving a dovetail projection 219 on the forward edge of the stock. Upon continued movement of the platens towards one another, the plate is constrained from movement by the engagement of its dovetail groove along the corresponding tongue 213 carried by the fixed blade. A magnet 223 is provided in the upper platen to prevent the cut plate from bending away from the platen. Each tongue 213 is spaced from the inside face of the corresponding plate 190 or 192. Thus, the plate is held by the dovetail projection 213 until the shearing action is complete and until just prior to initial penetration of its teeth into the joint. The plate is held by magnet 223 throughout the cutting and embedment operations. This ensures that the plate does not move from its intended location in the joint after being cut and prior to full embedment. The platens alternatively may be provided with spring biased plungers which straddle each plate on its opposite sides.
Referring to FIG. 12, there is illustrated a schematic diagram of a pneumatic circuit for the feed, stop, and clamp assemblies. The pneumatic circuitry is identical for each press assembly including the clamping and pilot cylinders as well as the lumber stops and clamps on opposite sides of the conveyor centerline. The pneumatic circuit for each press assembly and the clamps and stops associated therewith are illustrated within the dash lines. As illustrated, there is provided an air source 253 connected in parallel via a conduit 255 with five four-way, five-port, two-position solenoid actuated spring return valves 254L, 256, 258, 254R and 300. For brevity of description, the left and right hand circuit elements corresponding to the left and right hand press assemblies and the clamps and stops associated therewith are identified with reference numerals having letter suffixes L and R respectively. Valves 254L and 254R serve to provide air to the left and right pilot, stock clamp, and feed cylinders 156; 180; 182; and 124 respectively on opposite sides of the machine. Valve 256 provides air to web stops 102 and 105. Valve 258 provides air to chord stops 197 and valve 300 provides air to the lumber clamp cylinders 34. As illustrated, valves 254L and 254R are spring biased into the illustrated position wherein air is delivered to pilot cylinders 156 via conduits 259,260,262 and 264 to maintain the pilot cylinders in a retracted position with the pilot pins engaged between the teeth of the stock. Conduits 260 and 274 flow through a four-way two-position solenoid actuated spring returned valve 265 for purposes described hereinafter. Valves 254L and 254R also communicate air via lines 266, 268, 270 and 272 to the clamping cylinders 180 and 182 to maintain the latter in a retracted position. Air is also provided via flow control valve 271 and a time delay valve 273 to feed cylinder 124 to maintain it in a retracted position. It will be appreciated that the opposite sides of the various cylinders are exhausted to a reservoir via conduits which will now be described in connection with the actuation of the various cylinders.
Upon energization of the stock feed solenoids 326L and 326R associated with valves 254L and 254R respectively, the valves are shifted to provide air via conduits 275, 274, 276, and 278 to extend the pilot cylinders 156 whereby the pilot pins 152 are retracted from between the teeth of the stock. Air is also provided upper and lower clamping cylinders 180 and 182 respectively via conduits 280, 282 and 284 to extend grippers 184 and 186 whereby the upper and lower stock is clamped between the grippers and the jaws 168 and 170 respectively. Air is also provided feed cylinder 124 via conduit 280, flow control valve 286, and a time delay valve 288 to extend its piston whereby clamping assembly 128 and the stock clamped thereto is advanced. The opposite sides of the various pilot, clamp and feed cylinders communicate with a reservoir via the previously described conduits 268, 270, 266, 262, 264 260 and 259 when the solenoids 326 are energized.
In the rest position, valve 256 provides air to web stops 102 and 105 via conduits 290 and 292 whereby the stops are maintained in an extended position. Upon energization of the web stop solenoid 353, valve 256 shifts to provide air via conduits 294 and 295 to the opposite sides of stop cylinders 102 and 105 whereby stops 103 and 107 are retracted. Valve 25S is illustrated in a position providing air to the chord stop cylinders 197 via conduits 296 and 297. When the chord stop solenoid 354 associated with valve 25S is energized, valve 25S shifts to provide air via conduits 293 and 299 to the opposite ends of cylinder 197 to retract the stops 199.
Valve 300 is connected via a conduit 301 with the air supply. In the illustrated position, valve 300 supplies air to exhaust ports, which are plugged. Cylinders 34 and 34' are spring biased to maintain their clamp heads in a retracted position. Upon energization of the solenoid 311 associated with valve 300, the latter shifts to supply air via conduit 302 to each set of cylinders 34 and 34' to extend the heads 36, 36' against the side chords and clamp the latter against the web ends. Upon de-energization of solenoid 311, the spring returns the valve to the illustrated position with air being supplied to the plugged exhaust ports. The clamp heads then spring back to their retracted position.
Referring to FIG. 13, there is illustrated a hydraulic circuit for the press cylinders 214 and 215 and die set cylinders 111, 89U and 89L on each of the press assemblies. A variable displacement pump 230 supplies fluid from a reservoir 232 via a conduit 234 and through a directional control valve 236 to one side of the press cylinders 214 and 216 to maintain the press platens in a retracted position. Particularly, conduit 234 connects with a conduit 238 connected in parallel with the press cylinders on opposite sides of the machine via conduit 240 and 242. The opposite side of the press cylinders are connected via conduits 241, 243 with a flow divider 244 via relief valves 245 in each of lines 241 and 243. A conduit 246 communicates between the flow divider 242 and a reservoir 232 via valve 236. A pressure actuated switch 314 lies in communication with conduit 246. Motor 64 is connected between the reservoir 232 and motor 230 via a conduit 248, motor 64 running continuously and stalling when the chords butt the web stops 107.
Pump 230 also supplies fluid, via a conduit 370 and through a four-way two-position directional control valve 372 operated by a solenoid 374, to one side of the die actuating cylinders 111 and also to one side of the die punch actuating cylinders 89U and 89L via conduit 376 to maintain the various die cylinders normally fully retracted. The opposite sides of cylinders 111, 89U and 89L are connected via a conduit 378 to the reservoir 232. A delay valve 375 is disposed in line 378 between the die actuating cylinders 111 and the die punch actuating cylinders 89U and 89L.
In operation, hydraulic fluid is provided upper and lower press cylinders 214 and 216 and die set cylinders 111, 89U and 89L via conduits 238, 240, 242 and 370, 376, respectively. Upon energization of solenoid 310 associated with valve 236, the latter valve shifts to supply fluid to the flow divider 244 and to the press cylinders 214 and 126 via conduits 243 and 241 to extend the press platens carried thereby. Flow divider 244 serves to equalize the pressure of the fluid supplied the press cylinders to ensure uniform pressing action. Fluid flow returns to reservoir 232 from the opposite sides of cylinder 214 and 216 via conduits 240, 242, 238 and 246. Upon completion of the pressing action, the solenoid 310 is de-energized whereupon valve 236 is spring returned to the illustrated position. Fluid again flows to the press cylinders 214 and 216 via conduits 238, 240 and 242 to retract the platens and maintain them in a retracted position. Also, upon energization of solenoid 374 associated with valve 273, valve 372 shifts to supply fluid to the die actuating cylinders 111 and also to the die punch cylinders 89U and 89L via conduits 370 and 378 to extend the wedges 109 and die punches 93. Valve 375 serves to delay actuation of the die punch actuating cylinders 89U and 89L until the die actuating cylinders 111 have fully extended the wedge to fully displace the dies 101U and 101L. Fluid returns to reservoir 232 via conduits 376 and 378. Upon completion of the tooth formation in the stock strip, solenoid 374 is deenergized and valve 372 spring returns to its illustrated position enabling the cylinders 111, 89L and 89U to return to their normally retracted positions.
Referring now to FIG. 14 which is a schematic representation of an electrical control circuit for the fabricating machine hereof, the circuit is divided into several parts by dashed lines which indicate the functions of the circuitry enclosed by the dashed lines. The circuit is illustrated in a detached contact mode wherein the various relays represented by circles open and close associated contacts in a manner to be described, normally open and closed contacts being denoted by the pairs of parallel lines and the slashed pairs of parallel lines, respectively except where such notation is designated a switch. The contacts have numeral suffixes corresponding to the numeral suffixes of their actuating relay, the second numeral suffix indicating a particular contact. As noted previously, the electrical circuit has been divided by the dashed lines according to the various functions performed by the components thereof; the circuitry components within the dashed line indicated 304 controlling the pressing operation including the lumber clamps, the components within the dashed line indicated 305 controlling the feeding of the stock to the press assembly including the feed clamps therefor; and the components within the dashed line indicated 306 controlling the chord and web stops.
117 volts 60 cycle current is provided across lines 307 and 309 by a suitable power source P and which power source also provides power for hydraulic motors 64 and 230. Connected across the power source in line 311 is a power-on light 502, which indicates that the unit is energized. In line 307 there is provided a start switch 501. Connected in series across the power supply by a line 313 is a load solenoid 361, a fuse 312 and normally open contacts 315 which form part of a load switch 359. Line 313a couples a load switch 359a to supply line 307 and line 313 between contacts 315 and fuse 312. Connected in series by a line 363 connected to line 321 is the die set solenoid 374 and a fuse 365. Also connected in series by a line 316 is a press solenoid 310 and a fuse 317, line 321 connecting these elements across the power supply via normally open contacts 319 which form another part of the load switch 359. Connected in parallel with press solenoid 310 is a normally open contact Kl-1 in lead line 321 and a clamp solenoid 311 and a fuse 323 connected in series by line 325. Connected in series across the power supply by lines 316 and 327 are the normally closed contacts 314a of a nail pressure switch 314, normally open contacts Kl-3 and a relay Kl, line 321 connecting with line 327 between relay Kl and contacts Kl-3. Connected between lines 307 and 326 between contacts Kl-3 and 314a and by line 369 are the normally closed contacts 367 of a die actuator limit switch 376. Also connected between lines 307 and 326 between contacts Kl-3 and 314a, and in line 371 is the normally closed die punch fully extended switch 373. Between lead lines 369 and lead switch 359 there is provided a reset switch 329. A chord sensor switch 350 and normally open contacts K2-3 are connected in parallel across the power supply by lines 331 and 333, a fuse 335 and the chord stop solenoid 354 being connected in series in lead line 333. Also connected in series across the power supply by a line 337 is the normally open contact 314b of nail pressure switch 314, a fuse 339 and a web stop solenoid 353. Contacts 314a and 314b are mechanically linked whereby the closing of one set of contacts opens the other set. line 341 connects relay K2, normally open contacts K2-1, and a normally closed web limit switch 338 across the power supply. Line 342 connects with line 337 between normally open contacts 314b and fuse 339 and with line 341 between relay k2 and contacts K2-1. A normally open nailing switch 318 is disposed in line 321 and a nail enabling ligh 503 is connected by line 347 between lines 321 and 309. Connected in series across the power supply by line 351 are normally closed contcts 322a and 322a' of the right and left hand platen limit switch 322, the normally closed contacts 381a and 381a' of the right and left hand die punch limit switch 381, normally open contacts K3-3, a fuse 349 and the left and right hand stock feed solenoids 326L and 326R which are connected in parallel one with the other. A line 355 connects with line 351 between contacts K3-3 and die punch limit switch 381, line 355 containing normally closed contacts K3-2 and being connected to line 321 between the nail-switch 318 and light 503. Line 357 serially connects relay K3, normally open contacts 381b and 381b' of the die punch limit switch 381, normally open contacts 322b and 322b' of the platen limit switch, the contacts 322a and 322a' being mechanically connected to contacts 322b and 322b' respectively and the contacts 381a and 381a' being mechanically connected to contacts 322b and 322b' respectively. Connected in parallel across the platen limit switch 322 and die punch limit switch 381 and by a line 359 is a normally open contact K3-1 and a feed limit switch 320 having normally closed parallel connected contact sets.
The power-on light 502 indicates that power is available to the circuit. In operation, the start switch 501 is closed to provide power across lines 307 and 309. In this rest condition of the circuit with the power applied across lines 307 and 309, it will be appreciated that relays K1, K2 and K3, lead solenoid 361, press solenoid 310, clamp solenoid 311, chord and web stop solenoids 354 and 353, respectively, and the left and right hand stock feed solenoids are de-energized. The nails enabling light 503 is lighted by power supplied across lines 351, 355, and 347. To operate the mailing circuit, the nail switch 318 is momentarily depressed to energize relay K1 through lines 351, 355, 321 and 327. Energization of relay K1 closes normally open contacts K1-3 to complete holding circuits for relay K1 through lines 326 and 327 and normally closed contacts 314a or lines 326, 327 and 371 and normally closed contacts 373 or lines 326, 327 and normally closed contacts 369. Energization of relay K1 also closes normally open contact K1-1 whereby die solenoid 374 is energized through lines 326, 321 and 363, press solenoid 310 is energized through lines 321 and 316 and clamp solenoid 311 is energized through lines 321 and 325. The switch 376 opens contacts 367 in line 369 when the wedge 109 is fully extended and prior to the completion of the forming and pressing operations, the pressure actuated switch 314 opens normally closed contacts 314a and pin 121 opens the die punch fully extended switch 373 to de-energize the helding circuits for relay K1 which, upon de-energization, returns contacts K1-1 and K1-3 to their normally open positions. Opening contact K1-3 de-energizes the die, press and clamp solenoids 374, 310 and 311, respectively, whereupon the wedge and die punches are retracted, the press platens are returned to their normal retracted positions and the wooden frame is released in a manner to be described.
When the hydraulic pressure builds up in the press cylinders, normally open contacts 314b of nail pressure switch 314 close to energize relay K2 through lines 342 and 341 and to energize web stop solenoid 353 through line 337. Energization of relay K-2 closes normally open contacts K2-3 and K2-1. Closing contacts K2-1 completes a holding circuit for relay K2 through normally closed web limit switch 338 and line 341. Closing contacts K2-3 energizes chord stop solenoid 354. Thus, by energizing the chord and web stop solenoids 354 and 353 respectively, all stops are retracted. Upon advancement of a partially completed frame through the machine as hereafter more particularly described, the web limit switch 338 is opened de-energizing relay k2 which returns contacts K2-1 and K2-3 to their normally open positions and thereby de-energizing solenoids 353 and 354 allowing the stops to extend. However, if a chord of the partially completed frame is sensed by chord sensor switch 350, switch 350 closes to maintain chord stop solenoid 354 energized through line 331 and 333 whereby the chord stop is maintained retracted.
It will be recalled that, upon movement of the press platens toward one another, the normally open platen contacts 322b and 322b' closed and upon movement of the die punch plates 91U and 91L toward one another, the normally open die punch limit contacts 381b and 381b' closed whereby relay K3 is energized which in turn closes normally open contacts K3-1 and K3-3 and opens normally closed contact K3-2. Opening normally closed contact K3-2 de-energizes the nail enabling light 503 and also turns off the die forming and nailing command circuit. Closing normally open contacts K3-1 completes a holding circuit for relay K3 through lines 359 and 357 and the normally closed feed limit switch 320. Closing contacts K3-3, however, does not complete the circuit to the stock feed solenoids 326R and 326L as contacts 322a and 322a' of the platen limit switch 322 and contacts 381a and 381a' of the die limit switch 381 are held open until the platens and die punch plates return to their respective retracted positions. Upon their return, contacts 322a and 322a' and contacts 381a and 381a' return to their normally closed position thereby energizing the stock feed solenoids 326R and 326L through line 351. At the end of the stock feed stroke, the normally closed contacts 320 of the feed limit switch open to de-energize relay K3. De-energization of relay K3 returns contacts K3-1 and K3-3 to their normally open positions whereupon the stock feed solenoids 326R and 326L are de-energized. Contacts K3-3 also close, lighting the nail enable light and enabling the die forming and nail command circuit.
It will be appreciated that the metal strips are coiled on reels. Each reel includes a hub and a pair of spaced side plates 110 for confining the stock. The strips can be coiled in a single plane or spirally wound about the hub.
Operation
To operate the machine, the start switch 501 is closed to provide power to the electrical circuits illustrated in FIG. 14 within the dashed boxes 304, 305 and 306, the light 502 indicating the power is available. When these circuits are energized, the machine is at rest with the die actuating cylinders 111 and die punch actuating cylinders 89U and 89L retracted, the stock feed cylinder 124 retracted, the pilot cylinders 156 retracted with the pilot pins in the passages 146 and 148, the upper and lower clamp cylinders 20 and 182 retracted and the nail enable light lit. At rest, relays K1, K2 and K3 are de-energized and normally open contacts K3-3 maintain stock feed solenoids 326L and 326R de-energized and the valves 254L and 254R respectively associated therewith in the position illustrated in FIG. 10. Hydraulic valves 236 and 372 lie in the illustrated positions in FIG. 11 and the lumber clamps are retracted since normally open contact Kl-l and nail switch 318 prevent solenoid 311 from being energized. The web stop solenoid 353 is maintained de-energized through normally open contacts k2-1 and 314b and valve 256 supplies air to web stop cylinders 102 and 105 whereby stops 103 and 107 are maintained extended into the path of movement of the webs. However, without lumber on the machine, sensor switch 350 senses the lack of a chord on conveyor section 18, and thus remains open maintaining chord stop solenoid 354 in a de-energized condition and the chord stops 199 extended. The machine is now ready for loading.
The arbors 108 are placed within reel hubs 109 and the reels containing the coiled metal strips are placed on the upper and lower support brackets 76 and 78 on opposite sides of the machine with the pins 106 in slots 104. The reels are thus mounted for rotation but achieve a pendulum effect which prevents the reels from rotating of their own accord once the stock is fed to the machine. The strips are then led between rollers 131 and guides 127, and between the die punch and die of the die sets such that their leading ends are aligned with the forward ends of the die support plates 101U and 101L. Load switch 359 is then rotated to close contacts 315 thereby energizing solenoid 361. Energization of solenoid 361 shifts valve 265 to the left in FIG. 10 whereby air is provided cylinders 156 to extend the pistons and withdraw the pilot pins from passages 146 and 148. Rotation of load switch 359 also closes contacts 319 thereby energizing the die solenoid 374 and the press solenoid 310. Energization of die solenoid 374 causes the wedges 109 to extend and the die punches 93 to form teeth in the strips. Energization of solenoid 310 causes the press platens to move toward one another into a fully extended position blocking the ends of passages 198 and 200. Load switch 359 is then rotated to de-energize solenoid 361 which returns valve 265 to the position illustrated in FIG. 10 thereby returning the pins of the pilot cylinders to their extended positions in passages 146 and 148. Solenoids 310 and 374 are also de-energized enabling the die actuating cylinders 111, die punch actuating cylinders 89U and 89L, and press cylinders 214 and 216 to retract. Up a retraction of cylinder 111, the die support plates 105U and 105b (FIG. 11) move toward one another under the bias of spring 117 whereby the upper and lower dies are withdrawn from the teeth formed in the strips. Retraction of cylinders 89U and 89L also withdraws the die punches 93 from the strips in cooperation with the stripper plates 95. Also, upon movement of the press platens, contacts 322b and 322b' close to energize relay K3 which closes contacts K3-3 but which does not energize the stock feed solenoids since contacts 322a' are open. Return of the platens closes contacts 322a and 322a' to energize the stock feed solenoids 326R and 326L through line 351 and the closed contact K3-3. Upon energization of the stock feed solenoids, the pilot cylinders 156 extend to withdraw pins 152 from passages 146 and 148, the cylinders 180 and 182 extend and the feed cylinder 124 advances a predetermined distance toward the press platens. At the end of the feed stroke, feed limit switch 320 opens to de-energize relay K-3 and thereby return contact K3-3 to it normally open position whereupon the feed solenoids are de-energized. Upon spring return of valves 254R and 254L, the pilot cylinders retract to extend pins 152, the clamp cylinders retract, and the feed cylinder retracts after a time delay.
As will be recalled, the leading ends of the metal strips are initially aligned with the forward ends of the die support plates 101U and 101L and, of course, the aforedescribed feeding operation does not yet advance the the strips since the strips are not yet in engagement between the clamping heads 184 and 186 and the jaws 168 and 170. The strips are then manually advanced such that the trailing transverse rows of teeth are aligned with the forward ends of the die support plates. The lead switch is again rotated such that the die sets are actuated to form next groups of teeth in the strips, and the press heads are displaced toward one another. Load switch is then returned to its initial position causing the die cylinders 111, 89U and 89L and the press platens to retract. The feed assembly also completes another cycle. The manual feed is continued until the leading edge of the strip with the teeth formed therein is advanced to a location just short of the passages 146 and 148. Lead switch 359a is then closed to energize load solenoid 361 causing the pilot pins to retract from passages 146 and 148 (FIG. 4) and while retracted enabling further manual advance of the metal strips, with the leading edges thereof passing through passages 146 and 148, such that the trailing transverse rows of teeth are aligned with the forward ends of the die support plates. Load switch 359a is then opened and load switch 359 is again rotated whereupon the die sets form additional groups of teeth in the strips. Upon return of load switch 359 to the illustrated position, the press platens retract enabling the feed assembly to advance the strips. Subsequent additional rotations of load switch 359 advances the stock such that the leading ends thereof are cut off by the press platens whereupon predetermined lengths of connector stock are advanced to locations between the press platens upon the next feed cycle and which lengths define the lengths of connector plates which will be cut on the next operational cycle. The machine is thus loaded and ready for operation. It will be noted, however, that the pins 152 are inserted between a pair of transverse rows of teeth to adjust the longitudinal position of the stock in the press and also to hold the stock during shearing. Also, the pilot pins longitudinally adjust the location of the connector stock such that the teeth thereof are not aligned with the cutting blades. This prevents attempted shearing of the plate at the location of its teeth. If this was not prevented, the teeth per se might be sheared rendering them ineffective (as they would buckle upon attempted embedment in the wooden member). Also, the teeth might not shear at all as there is no reaction surface underlying the teeth for the movable cutting blade to act against due to the tines carried by the fixed cutting blade. The tines are, of course, necessary to guide the stock. Thus, the pilot pins ensure that the cut through the stock is made at a location between the teeth and only through the plate portion of the stock and not its teeth. Further, while the feed assembly as illustrated provides for maximum feed, it will be appreciated that sleeves of predetermined length can be disposed on the rods 162 whereby the stroke of the feed assembly can be limited to a predetermined length as desired. Thus, selected lengths of connector plates can be cut in a manner to be set forth from the stock fed into the machine. The machine is now ready for a pressing operation.
With reference to FIG. 15, a pair of precut chords C are disposed on table conveyor sections 18. The chords are then moved longitudinally along conveyor sections 18 into abutment with chord steps 199 as illustrated in FIG. 15a. A pair of precut web members W1 and W2 are then disposed between chords C on conveyor table section 18 and the first web W1 is manually moved forwardly into abutment against raised web stops 103. The second web W2 is spaced behind first web W1 a distance of about one foot (FIG. 16b). With the webs and chords thus positioned as in FIG. 15b, the operator depresses nail switch 318 to enerigize relay K1 and clamp solenoid 311, which closes normally open contact K1-3 to provide a holding circuit for relay K1 and clamp solenoid 311, and closes normally open contact K1-1 whereby die and press solenoids 374 and 310 respectively are energized. Energization of clamp solenoid 311 causes valve 300 to shift whereby air is supplied clamp cylinder 32 and 32' to extend clamp heads 36 and 36' carried thereby. Clamp heads 36 and 36' thus engage the outer faces of the chords and press the chords against the ends of web W1. Energization of die solenoid 374 shifts valve 372 (FIG. 13) to supply fluid to the die actuating cylinder 111 to extend wedge 109 between the die support plates 105U and 105L and thereafter through delay valve 375 to die punch actuating cylinders 89U and 89L to extend the die punches and form teeth in the metal strips. Energization of die solenoid 374 shifts valve 372 (FIG. 13) to supply fluid to the die actuating cylinder 111 to extend wedge 111 between the die support plates 105U and 105L to extend the die punches and form teeth in the metal strips. Energization of solenoid 310 shifts valve 236 to supply hydraulic fluid to upper and lower press cylinders 214 and 126, respectively, via the flow divider 244 whereby press platens 72 and 74 are moved toward one another.
Upon movement of platens 72 and 74 toward one another, the portions of the strip extending beyond the fixed cutting blades 194 and 196 are engaged by the platens and the movement of cutting blades 218 and 220 past blades 194 and 196 sever connector plates P from the stock S as illustrated in FIG. 9. An important feature hereof is the reaction force provided by the tines of the fixed blades whereby the stock is maintained rigid at the location of its cut. The connector plates P thus cut are carried by platens 72 and 74 toward one another and the teeth 402 thereof are embedded into the upper and lower sides of the joint formed by the chords and first web located previously between platens 72 and 74 by stops 199 and 103. See FIG. 15c.
Upon formation of the teeth in the metal strips, contacts 373 and 369 open but relay K1 is held energized through contacts 314a. Upon full embedment of the teeth the hydraulic pressure in the hydraulic circuit builds up and actuates pressure switch 314 to open contacts 314a. This de-energizes the holding circuit for relay K1 whereupon contacts K1-l and K1-3 return to their normally open position de-energizing die solenoid 374, press solenoid 310 and clamp solenoid 311. Valve 372 therefore shifts to supply fluid to die cylinders 111, 89U and 89L and retract the wedge 109 and the die punches and valve 236 shifts to supply hydraulic fluid to the press cylinders 214 and 216 to move the latens 72 and 74 away from one another and away from the completed joint. Air valve 300 also shifts to retract lumber clamps 32 and 32'.
Actuation of pressure switch 314 also closes contacts 314b to energize relay K2 and web stop solenoid 353. Energization of relay K2 closes normally open contacts K2-3. Relay K2 is maintained energized by a holding circuit through contact K2-1. Closing contact K23 energizes chord stop solenoid 354. Energization of solenoids 353 and 354 causes valves 256 and 258, respectively, to shift whereby air is supplied to the web stop cylinders 102 and 105 and the chord stop cylinders 197 thereby to retract stops 103, 107 and 199, respectively carried thereby.
The partially completed frame is then manually advanced (FIG. 15d) below power roller 16 which thereafter carries the partially completed frame forwardly. Open advancement of the partially completed frame, web W1 momentarily opens web limit switch 338 to de-energize the holding circuit for relay K2 whereupon contact K2-1 is returned to its normally open position de-energizing web stop solenoid 353 and causing web stops 103 and 107 to be extended. In advancing the partial frame, the chords are advanced to engage and close the chord sensor switch 350 causing continued energization of the chord stop solenoid 354 through line 321 and hence continued retraction of stop 199. The partially completed frame continues to advance until web W1 butts extented stops 107. Extended web stops 103 catch and retain the second web in the position illustrated in FIGS. 15d and 15e whereupon it becomes aligned with the trailing ends of the chords.
After the die punches 93 are retracted, the die punch limit switch 381 returns contacts 361a and 381a' to their normally closed position and contacts 381b and 381b' to their normally open position. Also, after the press platens 72 and 74 are retracted, the retracted platen switch 322 returns contacts 322a and 322a' to their normally closed position and contacts 322b and 322b' to their normally open position.
It will be recalled that initially relay K3 was not energized. Upon initial movement of the die punches and press platens from their rest positions, however, contacts 381b, 381b', 322b and 322b', close and energize relay K3. Contacts K3-1 hold relay K3 energized through the normally closed contacts of feed complete switch 320. Normally closed contacts K3-2 open upon energizing relay IK3 and disconnect the nail switch 318 from the nail feed circuitry and from its source of power, preventing operation of the die sets and press platens and turning off the nail enable light 503. The normally open contacts K3-3 close upon energizing relay K3 and provide a path to the stock feed solenoids 326R and 326L through the now open platen retracted limit switches 322a and 322a' and die punch limit switches 381a and 381b'. Thus, when the die punches and press platens retract, and the platen limit switch 322 and die punch limit switch 381 are in their normal positions, stock feed solenoids 326L and 326R are energized through contacts 381a, 381b', 322a' and closed contacts K3-3. Consequently, upon return of die punch limit switch 381 and platen switch 322 to their normal positions as illustrated, the stock feed solenoids 326R and 326L are energized to shift valves 254 to supply air to the pilot cylinders 136 and the upper and lower clamp cylinders 180 and 182. The upper stock is clamped between grippers 186 and jaw 168 while the lower stock is clamped between gripper 184 and jaw 170. It will be noted that the clamping action is only on the surface of the plate and not against the teeth because of the tines in jaws 168 and 170, respectively. Also, the pilot cylinder pistons extend to retract the pilot pins 152 from between the longitudinally adjacent transverse rows of teeth. With the stock clamped and properly located relative to the cutting edges, feed cylinder 124 advances after a slight time delay to advance the stock a distance beyond the fixed cutting edges equal to the distance of the stroke of cylinder 124 (which may be adjusted by inserting one or more sleeves of selected length about rods 162). Upon completion of the feed stroke, normally closed feed limit switch 320 is momentarily opened thereby de-energizing relay K3 and opening normally closed contact K3-3 and closing normally closed contact K3-2, whereupon stock feed solenoids 326L and 326R are de-energized. Power is also supplied to nail switch 318 and nail enable light 503. This enables the nail circuit for subsequent nailing. Upon de-energization of solenoids 326R and 326L, valve 254 spring returns to the position illustrated in FIG. 10 whereupon the pilot cylinder pistons retract to insert the pilot pins between the transverse rows of teeth of the advanced stock, the upper and lower clamp cylinders retract to release the stock and the feed cylinder retracts to withdraw the clamp assembly 128 to the dashed line position illustrated within FIG. 4 preparatory for another feed.
It will be appreciated that the pilot pins are inserted prior to retraction of the clamp assembly. As noted previously, the pilot pins serve to adjust the longitudinal location of the connector stock, as necessary, to avoid alignment of the teeth with the cutting edges. When the clamp assembly is retracted, the pilot pins thus longitudinally adjust the location of the stock relative to the cutting blades and also hold it in such position until the pins are again retracted after the next cut is made.
Since the partially completed frame is now located in position for applying connector plates to the joint between the second web W2 and the trailing ends of the chord, nail switch 318 is again depressed whereupon the die sets are actuated to form teeth in the metal strips and the press heads 72 and 74 substantially simultaneously shear connector plates from the connector strips and embed the teeth thereof into the opposite sides of the joint on each side of the frame. Upon retraction of the die cylinders and press platens, the feed mechanism again operates to locate predetermined lengths of connector stock beyond the fixed cutting blades and between the press platens and the completed frame is advanced along the conveyor away from the machine by the power roller. Upon removal of the completed frame, the chord sensor switch 350 opens to de-energize solenoid 354 whereupon the chord stops are extended. The machine is thus ready for the fabrication of a second frame. It will be recalled that stops 103 and 107 are returned to their extended positions by the momentary opening of the web limit switch 338 which permits de-energization of the web stop solenoid 353.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Claims

1. A method for joining a pair of wooden members by applying a sheet metal connector plate, of the type having integrally struck teeth projecting from one side thereof, to the wooden members at their juncture comprising the steps of:
providing a coiled strip of sheet metal,
feeding the metal strip from the coil through a die set,
actuating said die set to form teeth in the metal strip,
feeding the metal strip with the teeth formed therein into the path of movement of a presshead carrying a cutting edge thereby defining relative to the cutting edge a predetermined line of cut along the metal strip,
providing a reaction surface cooperable with the cutting edge and comprising a guide surface with a plurality of tines defining a plurality of laterally spaced recesses,
locating and guiding the teeth of the strip along the recesses as the strip is fed into the path of movement of the presshead, engaging the strip to the tines with the teeth of the strip within the recesses of the tines
advancing the tines to feed the strip into the path of movement of the presshead,
displacing the presshead to engage the cutting edge and reaction surface tines along opposite sides of the strip and along its predetermined line of cut and, upon continued displacement of the presshead, cutting the strip to form a connector plate of predetermined length, and
pressing the teeth of the connector plate thus formed into one side of the adjoining wooden members upon continued displacement of the presshead in the same stroke thereof.
2. The method according to claim 1 including:
providing a second coiled strip of sheet metal,
feeding the metal strip from the coil through a second die set,
actuating said second die set to form in said second metal strip,
feeding the second metal strip with the teeth formed therein into the path of movement of a second presshead carrying a cutting edge a predetermined line of cut along the metal strip, said second presshead lying in opposition to said first presshead,
providing a second reaction surface cooperable with the cutting edge of the second presshead and comprising a guide surface with a plurality of tines defining a plurality of laterally spaced recesses,
locating and guiding the teeth of the second metal strip along the latter recesses as such strip is fed into the path of movement of the second presshead,
engaging the strip to the tines with the teeth of the strip within the recesses of the tines
advancing the tines to feed the strip into the path of movement of the presshead,
displacing the second presshead to engage the cutting edge and reaction surface tines along opposite sides of the second strip and along its predetermined line of cut and, upon continued displacement of the second presshead, cutting such strip to form a second connector plate of predetermined length, and
pressing the teeth of the second connector plate thus formed into the opposite side of the adjoining wooden members.
3. The method according to claim 2 including substantially simultaneously pressing the teeth of the first and second connector plates into respective opposite sides of the members with each presshead providing a reaction force for the other.
4. The method according to claim 1 including locating a pair of wooden members in opposition to said presshead, and clamping the wooden members in butting relation one to the other prior to pressing the teeth of the connector plate into the wooden members.
5. The method according to claim 1 including adjusting the location of the leading portion of the metal strip relative to the cutting edge such that the cut is made between two transverse rows of teeth.
6. The method according to claim 1 wherein the presshead is movable from a retracted position to an extended position for cutting the metal strip and embedding the teeth of the plate into the wooden members and from the extended position for return to the retracted position, and including
actuating the feed means in response to movement of said presshead from said extended position to said retracted position and completion of the teeth forming operation to feed the metal strip into the path of movement of the presshead.
7. The method according to claim 1 including
providing a guide surface comprised of a plurality of tines defining a plurality of laterally spaced recesses, locating the teeth of the metal strip within the recesses,
clamping the strip to the latter tines with the teeth of the strip within the latter recesses by engaging a clamp against the strip on the side thereof opposite the tines,
advancing the tines and the clamp to feed the strip into the path of movement of the presshead, the presshead being movable from a retracted position to an extended position for cutting the strip and embedding the teeth of the plate into the wooden members and from the extended position for return to the retracted position,
and actuating the feed means in response to movement of said presshead from said extended position to said retracted position and completion of the teeth forming operation to feed the metal strip into the path of movement of the presshead.
8. A method of joining a pair of wooden members by applying a sheet metal connector plate, of the type having integrally struck teeth projecting from one side thereof, to the wooden members at their juncture comprising the steps of:
providing a coiled strip of sheet metal,
feeding the metal strip from the coil through a die set,
actuating said die set to form teeth in the metal strip,
providing a guide surface comprised of a plurality of tines defining a plurality of laterally spaced recesses,
locating the teeth of the metal strip within the recesses,
clamping the metal strip to the tines with the teeth of the strip within the recesses by engaging a clamp against the strip on the side thereof opposite the tines.
advancing the tines and the clamp to feed the metal strip into the path of movement of a presshead,
cutting the metal strip to form a connector plate of predetermined length, and
pressing the teeth of the connector plate thus formed into one side of the adjoining wooden members.
9. The method according to claim 8 wherein the steps of cutting the metal strip and embedding the teeth of the connector plate are performed in the same stroke of the press.
10. The method according to claim 8 including:
providing a second coiled strip of sheet metal, feeding the second metal strip from the coil through a second die set, actuating said second die set to form teeth in the metal strip,
providing a second guide surface comprised of a plurality of tines defining a plurality of laterally spaced recesses,
locating the teeth of the connector stock from the second coil within the latter recesses,
clamping the metal strip to the latter tines with the teeth of the second strip within the latter recesses by engaging a clamp against such strip on the side thereof opposite the tines,
advancing the second tines and the clamp to feed the second metal strip from the second coil into the path of movement of the second presshead,
cutting the second metal strip to form a second connector plate of predetermined length,
and pressing the teeth of the second connector plate into the opposite side of the adjoining wooden members.
11. The method according to claim 10 wherein the steps of embedding the teeth of the first and second connector plates in the opposite sides of the members are accomplished substantially simultaneously with each providing a reaction force for the other, wherein the steps of cutting the first metal strip to form the first connector plate and embedding the teeth thereof are performed in the same stroke of the first presshead, and wherein the steps of cutting the second metal strip to form the second connector plate and embedding the teeth thereof are performed in the same stroke of the second presshead.
12. The method according to claim 8 including locating a pair of wooden members in opposition to said presshead, and clamping the wooden members in butting relation one to the other prior to pressing the teeth of the connector plate into the wooden members.
13. The method according to claim 8 including adjusting the location of the leading portion of the metal strip with the teeth formed therein relative to the cutting edge such that the cut is made between two transverse rows of teeth
14. The method according to claim 13 including rendering the metal strip movable in a direction corresponding to its longitudinal extent, and inserting an element between longitudinally spaced teeth to engage such teeth and displace the strip longitudinally to adjust its location relative to the cutting edge.
15. The method according to claim 8 wherein the presshead is movable from a retracted position to an extended position for cutting the metal strip and embedding the teeth of the strip into the wooden members and from the extended position for return to the retracted position,
actuating said feed means in response to movement of said presshead from said extended position to said retracted position and upon completion of the teeth forming operation to feed the metal strip into the path of movement of the presshead.
16. The method of joining a pair of wooden members by applying a sheet metal connector plate, of the type having integrally struck teeth projecting from one side thereof, to the wooden members at their juncture comprising the steps of:
providing a coiled strip of sheet metal,
feeding the metal strip from the coil through a die set,
actuating said die set to from teeth in the metal strip,
rendering the metal strip movable in a direction corresponding to its longitudinal extent so that the metal strip is fed to a presshead carrying a cutting edge,
adjusting the location of the leading portion of the metal strip with the teeth formed therein relative to the cutting edge by inserting an element between longitudinally spaced teeth to engage such teeth and displace the strip longitudinally such that the cut is made between two transverse rows of teeth,
cutting the metal strip to form a connector plate of predetermined length, and
pressing the teeth of the connector plate thus formed into one side of the adjoining wooden members.
17. The method according to claim 16 wherein the steps of cutting the metal strip and embedding the teeth of the connector plate are performed in the same stroke of the presshead.
18. The method according to claim 16 including the steps of:
providing a second coiled strip of sheet metal,
feeding the second metal strip from its coil through a second die set, actuating said second die set to form teeth in said second metal strip, feeding the second metal strip with the teeth formed therein into the path of movement of a second presshead carrying a cutting edge and in opposition to said first presshead,
adjusting the location of the leading portion of the second metal strip relative to the cutting edge of the second presshead such that the cut is made between two transverse rows of teeth,
cutting the second metal strip to form a second connector plate of predetermined length, and
pressing the teeth of the second connector plate into the opposite side of the adjoining wooden members.
19. The method according to claim 18 wherein the steps of embedding the teeth of the first and second connector plates into opposite sides of the members are accomplished substantially simultaneously with each providing a reaction force for the other, wherein the steps of cutting the first metal strip to form the first connector plate and embedding the teeth thereof are performed in the same stroke of the first presshead, and wherein the steps of cutting the second metal strip to form the second connector plate and embedding the teeth thereof are performed in the same stroke of the second presshead.
20. The method according to claim 16 including locating a pair of wooden members in opposition to said presshead, and clamping the wooden members in butting relation one to the other prior to pressing the teeth of the connector plate into the wooden members.
21. The method according to claim 16 including providing a guide surface comprised of a plurality of tines defining a plurality of laterally spaced recesses; locating the teeth of the strip within the recesses; clamping the strip to the tines with the teeth of the strip within the recesses by engaging a clamp against the strip on the side thereof opposite the tines, and advancing the tines and the clamp to feed the strip into the path of movement of the presshead.
22. The method according to claim 16 wherein the presshead is movable from a retracted position to an extended position for cutting the strip and embedding the teeth of the plate into the wooden members and from the extended position for return to the retracted position, actuating said feed means in response to movement of said presshead from said extended position to said retracted position and upon completion of the teeth forming operation to feed the metal strip into the path of movement of the presshead.
23. The method according to claim 16 including providing a guide surface comprised of a plurality of tines defining a plurality of laterally spaced recesses; locating the teeth formed in the metal strip within the recesses; clamping the strip to the tines with the teeth of the strip within the recesses by engaging a clamp against the strip on the side thereof opposite the tines, advancing the tines and the clamp to feed the metal strip into the path of movement of the presshead, the presshead being movable from a retracted position to an extended position for cutting the strip and embedding the teeth of the plate into the wooden members and from the extended position for return to the retracted position, and actuating said feed means in response to movement of said presshead from said extended position to said retracted position and upon completion of the teeth forming operation to feed the metal strip into the path of movement of the presshead.
24. A method of joining a pair of transversely spaced generally parallel elongated wooden side members and a pair of elongated longitudinally spaced intermediate wooden members disposed between said side members in generally perpendicular relation thereto by applying a sheet metal connector plate, of the type having integrally struck teeth projecting from one side thereof, to each of the joints between the side and intermediate wooden members comprising the respective steps of:
providing first and second coiled strips of sheet metal, feeding the strips from the coils through respective die sets, actuating said die sets to form teeth in the metal strips,
providing guide surfaces comprised of a plurality of tines defining a plurality of laterally spaced recesses for guiding each strip, locating the teeth of each strip within the associated recesses, clamping each strip to its associated tines with the teeth of such strip in the recesses therebetween, and advancing each of the tines and clamp to feed the associated strip into the path of movement of the corresponding first and second presshead,
each presshead being moveable along a predetermined path from retracted to extended positions and carrying a cutting edge,
locating the joints between the side members and the first intermediate member in the respective paths of movement of said first and second pressheads,
feeding additional portions of the metal strips through the respective die sets, actuating the die sets to form teeth into the additional portions of the metal strips, feeding additional portions of the strips with the teeth formed therein into the respective paths of movement of said first and second pressheads,
cutting the strips to form third and fourth connector plates of predetermined length in response to movement of the pressheads from their retracted positions towards their extended positions, and pressing the teeth of the connector plates thus formed into the respective joints of the side members and second intermediate member.
25. The method according to claim 24 wherein the steps of cutting the metal strips and embedding the teeth of each connector plate are performed in the same stroke of the associated presshead.
26. The method according to claim 24 including clamping the side and first members in butting relation one to the other prior to pressing the teeth of the first and second connector plates into the joints formed therebetween, and clamping the side of second members in butting relation one to the other prior to pressing the teeth of the third and fourth connector plates into the joints formed thereby.
27. The method according to claim 24 including providing a reaction surface cooperable with each cutting edge and comprised of a plurality of tines defining a plurality of spaced recesses, guiding the teeth of each strip along the recesses of its associated reaction surface as the strip is fed into the path of movement of the corresponding presshead, and displacing each presshead to engage its associated cutting edge and reaction surface tines along opposite sides of the corresponding strip and, upon combined displacement thereof, cutting such strip.
28. The method according to claim 24 including adjusting the location of the leading portion of each strip with the teeth formed therein relative to the associated cutting edge such that the cut is made between two transverse rows of teeth of such strip.

Parent Case Info

This application is a divisional application of Ser. No. 565,756, now U.S. Pat. No. 3,985,278, which application is in turn a continuation-in-part of application Ser. No. 488,066, filed Dec. 12, 1974, now U.S. Pat. No. 3,913,816, which application Ser. No. 488,066 is a continuation of application Ser. No. 317,095 filed Dec. 20, 1972, now abandoned.

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Number	Name	Date
529752	Saltzkorn et al.	Nov 1894
598307	Leffler	Feb 1898
2885679	Stanwyck	May 1959
3068483	Moehlenpah et al.	Dec 1962
3086210	Good et al.	Apr 1963
3088381	Paist et al.	May 1963
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Divisions (1)

	Number	Date	Country
Parent	565756	Apr 1975

Continuations (1)

	Number	Date	Country
Parent	317095	Dec 1972

Continuation in Parts (1)

	Number	Date	Country
Parent	488006	Dec 1974

Method of joining wooden members

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