This invention relates to systems and methods used to assemble trusses. More specifically, the present pertains to the automated assembly of trusses composed of wooden components.
A typical truss 10 fabricated from wooden components is illustrated in
In larger manufacturing facilities, the specifications of the trusses to be manufactured are entered into the controller of the saw system including data such as the total number of trusses, the total number of each truss component, the length of each component and the angle of the ends of the components. The controller may be programmed to cut all the components of a single truss or component by component. In such a case the components are bundled then taken to an assembly station where the trusses are manually assembled. First, the cord members 11A, 11B are assembled to form the perimeter. Thereafter, the web members 12 are positioned between the cord members 11 and secured thereto in order from left to right, or from right to left. These steps take a considerable amount of manpower and time. Presently, there does not exist a system or method for the automated assembly of a truss.
The features of the invention believed to be novel are specifically set forth in the appended claims. However, the invention itself, both as to its structure and method of operation, may best be understood by referring to the following description and accompanying drawings.
Exemplary embodiments of the present invention solves the problems in the art by providing a system, method, and computer software code, for improving operating capabilities of a automated truss assembly system. Persons skilled in the art will recognize that an apparatus, such as a data processing system, including a CPU, memory, I/O, program storage, a connecting bus, and other appropriate components, could be programmed or otherwise designed to facilitate the practice of the method of an exemplary embodiment of the invention. Such a system would include appropriate program means for executing the method.
An embodiment of the present invention for a system 13 and method for the automated assembly of trusses is shown in the schematic of
The system 13 is particularly useful in the assembly of large numbers of trusses. For example, a single job may require the assembly of as many as one hundred trusses or more. In such cases, the trusses are assembled in the order in which the trusses will be loaded onto a truck. In an embodiment, the system may include one or more of a plurality of controllers. Each of the controllers are incorporated in the assembly system and are programmed with a specification to control the assembly of a plurality of trusses. In addition, the controllers are programmed with a specification to cut, stage and/or assemble a total number of trusses 10 that includes a total number of cord members 11A, 11B and web members 12 to complete the job. Further, the controllers may be programmed to identify each truss 10, cord member 11 and/or each web member 12 in the order in which they are to be cut and assembled and may monitor the production of the trusses 10 so that one may determine the number of trusses 10 assembled at any time during production.
In an embodiment, the system includes eight controllers. More specifically, there are one or more controllers, such as controllers 28 and 29, for the automated saw systems 17,18, a main controller 30, a controller 31 for web presenter 90, controller 104 for the main robotic arm 101, controllers 41, 44 for the presses 71A, 71B. The databases of controllers 28 and 29 include data relative to the dimensions of the truss components including the length and width of a component, and the angle of cut to be made at either end of a component. The saw systems 17 and 18, in response to appropriate input commands, cut the cord members 11 and web members 12 respectively according to the entered data. It is contemplated that communications delivered to any of the controllers of the system may be directed to the particular controller directly or indirectly through the main controller 30.
The database of main controller 30 in the second station 15 includes a specification, including data, associated with the position of cord members 11A, 11B, i.e., the angle, relative to one another. In addition, the main controller 30 may include a specification, including data, relative to where a web member 12 is positioned on the truss 10 including a point or points where a web member 12 is attached to cord members 11A, 11B and an angle at which a web member 12 is disposed relative to the cord members 11A, 11B. The main controller 30 may be linked to any one or more of the other controllers by Ethernet or any other suitable method of communication known in the art for providing communication between one or more of the other controllers to the main controller 30.
With respect to the embodiment shown in
The saw systems 17, 18 include an entrance roller table 24 and an exit roller table 25 that have a plurality of rollers rotatably mounted on a frame. In this manner, a work piece such as a piece of lumber can be linearly fed into and out of a cutting zone in each of the saw systems 17, 18. In the first station 14, pieces of lumber 23, 27 are placed on automated feeders 22 and 26, which have a plurality of rotating belts or chains mounted to a frame and rotate in a direction perpendicular to the linear movement of the lumber 23, 27 on the roller tables 24 of the saw systems 17, 18 respectively.
The operation of the saw system 17 relative to the first station 14 and the second station second 15, and components therefore, are now described in more detail. The saw system 17 is used to cut the cord members 11A, 11B. Pieces of lumber 23, taken from lumber carts 40 are placed on the feeder 22, which transports the lumber to entrance roller table 24 and into a cutting zone of the saw system 17. As described above, the controllers are programmed to generate a signal identifying the particular truss, i.e., the first truss, to be built, which truss includes a predetermined number of top cord members 11A and a predetermined number of bottom cord members 11B. In addition, one or more signals are generated that are indicative of the position of a saw blade (not shown) relative to the lumber; and, the saw system 17 cuts the cord members 11A and 11B responsive to the signals and in accordance with the data that represents the dimensions of a cord member 11A, 11B.
The example of the truss 10 shown in
In the embodiment described herein, the controllers are programmed so the bottom cord members 11B are cut first before the top cord members 11A are cut. However, the order in which the cord members 11A and 11B may depend on the location of the saws 17, 18 relative to the assembly table 20. Indeed, as described in U.S. Provisional Application No. 60/886,147, which is incorporated by reference herein, the top cord members are cut prior to the bottom cord members. After the lumber 23 is cut, the cord members 11A, 11B exit the cutting zone on the exiting roller tables 25 and are transported to the assembly table 20 via conveyors 19A and 19B. Optionally, a splicer 32 may be positioned next to the conveyor 19A to fasten the two bottom cord members 11B to one another and the top cord members 11A to one another for assembly of the truss 10 in the second station 15. The fastening step is intended to maintain the cord members 11A and cord members 11B in abutting relationship during assembly. In addition, the top cord members 11A are moveable with respect to one another to form the apex 122 of the truss 10. Connector plates 72, as will be described in more detail, are pressed onto the truss 10 later in the assembly process to affix the cord members 11A and 11B together.
Again with respect to
A sensor 35 is positioned toward an end of the conveyor 19A and is in communication with a controller 28-30 and servomotors (not shown) to detect the presence of an approaching cord member 11A, 11B. The controllers 28, 30 and/or sensor 35 have a processor (not shown) that is programmed to activate the servomotors and transfer chains 33 when a cord member 11A, 11B is detected at a predetermined distance from the sensor 35 or an end of the conveyor 19A. The transfer chains 33 are disposed in a first position below the conveyor 19A as the cord members 11A, 11B travel along the conveyor 19A. When activated, the transfer chains 33 are elevated between consecutive rollers on the conveyor 19A, engaging the cord members 11A and transferring the cord members 11A to the assembly table 20.
With respect to the bottom cord members 11B, when the controller 28 or 30 signals the transfer chains 33 to be elevated, the controller 28 or 30 is programmed to maintain the transfer chains 33 in the second or elevated position a predetermined time which is sufficient for the bottom cord members 11B to travel along the transfer chains 33 until the bottom cord members 11B fall off the transfer chains 33 at a predetermined location of the assembly table 20. Alternatively, a second sensor (not shown) is positioned on the assembly table 20 that detects the presence of the bottom cord member 11B and generates a signal. The controller 28 or 30, in response to this signal and/or after a predetermined amount of time has elapsed, is programmed to lower the transfer chains 33 to cause the bottom cord members 11B to fall off an end of the transfer chains 33 and onto the assembly table 20.
Similarly, with respect to the top cord members 11A, when the controller 28 or 30 signals the transfer chains 33 to be elevated, the controller 28 or 30 is programmed to maintain the transfer chains 33 in the second or elevated position for a predetermined amount of time which is sufficient for the top cord members 11A to travel along the transfer chains 33 until the top cord members 11A fall off the transfer chains 33 at a predetermined location of the assembly table 20. Alternatively, a second sensor (not shown) is positioned on the assembly table 20 that detects the presence of the top cord member 11A and generates a signal. The controller 28, in response to this signal and/or after a predetermined amount of time has elapsed, is programmed to lower the transfer chains 33 to cause the top cord members 11A to fall off an end of the transfer chains 33 and onto the assembly table 20.
The assembly of cord members 11A, 11B in the second station 15 is described now in more detail. The top cord members 11A and bottom cord members 11B, as shown in
With respect to
A vector cam (clamping device) 21A or 21B is illustrated in more detail in FIGS. 4 and 6-8. Referring to
As shown in
Referring to
As is particularly shown in
With respect to
As shown in
The roller guides 42A, 42B have similar components as the above-described vector cams 21A, 21B. Accordingly, the description of above vector cams 21A, 21B applies to the roller guides 42A, 42B, with the exception that the roller guides 42A, 42B do not include the register 49 or the electric clutch 68. In addition, the rollers 50 on the roller guides 42A, 42B are positioned on the cylinder block 53 to engage an outside edge of the cord members 11A, 11B, as shown in
The operation of the vector cams 21A, 21B and roller guides 42A, 42B in positioning the cord members 11A and 11B on the assembly table 20 is now discussed in more detail in reference to FIGS. 3 and 10-13. In the embodiment shown in
At the outset, when the entire system 13 is started to assemble trusses 10, each of the controllers 28, 29, 30 is programmed to identify each truss component used to assemble a truss 10, and each truss 10 that has been assembled. Accordingly, as the cord members 11A and 11B are staged on the assembly table 20 as described above, the vector cams 21A, 21B are aligned with the cord members 11A, 11B for receiving cord members 11A, 11B as the rolling pins 36 advance the boards.
With respect to
In an embodiment of the invention, the bottom cord member 11B is advanced along the assembly table 20 before the top cord member 11A, because the angle at which the top cord member 11A is positioned relative to the bottom cord member 11B, and the position of the vector cams 21A and roller guides 42A on the track is based on a point of origin 113 taken from an edge of the bottom cord member 11B as shown in
The top cord members 11A are then advanced so the registers 49 on the vector cams 21A, 21B begin rotating. With respect to
When the sensor 56 (through-beam sensor) detects the presence of the top cord member 11A, a signal is generated and sent to the controller 30, which identifies the board as a top cord member 11A. The controller 30 generates one or more signals in response to which the registers 49 stop rotating and reverse rotation to back the top cord member 11A a predetermined distance. In addition, the one or more signals are indicative of a position/angle of each vector cam 21A on the assembly table 20 relative to a position the top cord members 11A. Responsive to these signals, the mounting plate 52 and rollers 50 on vector cams 21A and roller guides 42A pivot with respect to the arm 48 to position the top cord member 11A at a predetermined angle with respect to the bottom cord member 11B. As shown in
In addition, as shown in
As mentioned above the controller 30 is programmed to identify each truss 10 that is being assembled including identifying each cord member 11A, 11B and web member 12 that is used in the assembly process. To that end, the controller 30 includes data that represents particular tasks that must be performed and the order in which such tasks must be performed. In addition, the controller 30 records the performance of each task.
The data input into the controller 30 or recorded by the controller 30 also includes data representative of where the truss components 11A, 11B and 12 are to be positioned relative to one another (and/or relative to the point of origin 113 as referred to herein) and/or relative to one or more reference points on the assembly table 20. In addition, the data also includes data relative to the position of the system components such as the vector cams 21A, 21B, guide rollers 42A, 42B, presses 71 (described below) and robotic stable guns 230 (described below) or other components, relative to the truss components 11A, 11B and 12, and/or relative to one or more reference points on the assembly table 20. Accordingly, the controller 30 is programmed to generate signals representative of the position of the system components on the assembly table 20 necessary to perform a particular task. Once that task is performed, the controller 30 generates signals necessary to reposition certain components as necessary to perform a subsequent task.
By way of example, and in reference to
After the components 11A, 11B are stapled together, the truss 10 is advanced on the table a predetermined distance where a press 71A, 71B (described below) is positioned to attach connector plates 72 to the corner of the truss 10. After the connector plates 72 are affixed to the corner of the truss 10, the truss 10 is advanced a predetermined distance so a web member 12, as shown in
As the truss 10 advances on the table 20, the roller guides 42A and vector cams 21A are repositioned on the table 20 to maintain the top cord member 11A in its predetermined position relative to the bottom cord member 11B. As shown in
As shown in
As shown in
In connection with the assembly of trusses using the present system, an automated press 71 is provided that moves back and forth on the assembly table 20 to affix connector plates 72 to the truss 10 to secure the web members 12 to cord members 11A, 11B or to affix cord members 11A and/or 11B to one another. With respect to
As shown in
As shown in
In addition, the presses 71A, 71B are mounted for back and forth lateral movement on an overhead rail 124 for positioning the presses 71A, 71B relative to a truss 10 to attach connector plates 72 to the truss 10. The presses 71A, 71B are mounted on the overhead rail 124 and the presses 71A, 71B are positioned adjacent the assembly table 20. To enable lateral movement of the presses 71A, 71B on overhead rail 124, presses 71A, 71B each include a press alignment system 126.
As shown in
In addition, each upper frame portion 128 includes a servo-driver 146 for driving the disc 130 and presses 71A, 71B forward and backward on overhead rail 124 as described below. Specifically, servo-driver 146 includes a rotating spindle 148 and a wheel 149. The wheel 149 has having a plurality of spaced apart circular plates 151 with pins 150 disposed between the plates 151 that engages a track 158 (similar to track 45) that extends longitudinally adjacent a center of the I-beam member 144.
As shown in
The back and forth movement of the press 71, lateral movement of the bottom platen 75, and vertical (up/down) movement of the top platens 73 is triggered by trip switches in communication with the servo-driver 146, pneumatic cylinders, and controllers 30, 41, or 44 that control or manage movement of the presses 71A, 71B and press components. The controller 30 identifies where the truss 10 is in the assembly process including the position of where the truss 10 is on the table 20. More specifically, the controller 30 has a database having data stored that is representative the number of each size connector plate 72 to be placed on a given truss 10 and the location of where each connector plate 72 is positioned on each truss 10.
As described in more detail below, two robotic arms 85, each disposed adjacent a respective press 71A, 71B transfers connector plates 72 from a bin assembly 86 to the presses 71A, 71B for installation. The robotic arm 85 is mounted on a base 87 and takes connector plates 72 from the bin assembly 86 as shown in
Subsequently, the top platen 73 lowers and engages the top connector plate 72A and then the top platen 73 is raised holding the top connector plate 72A spaced above the second connector plate 72B, which remains on the bottom platen 75. The controller 30, 41, or 44 then generates a signal that is indicative of a location on the truss 10 where the connector plates 72A, 72B are to be affixed to the truss 10, or the signal may be indicative of the distance the press 71A or 71B must travel on the overhead rail 124. Responsive to this signal, the servo-driver 146 drives the press 71A, 71B into position for attachment of the connector plates 72A to the truss 10. The top platen 73 and bottom platen 75 stamp the connector plates 72A, 72B into place on the truss 10.
The balance springs 78 may be positioned on the press 71A to support the bottom platen 75 such that when the top platen 73 is lowered, the springs 78 adjust the bottom platen 75 upward to engage the truss components. In this manner, the truss components are not depressed downward below a plane of the assembly table 20 when the press 71 installs the connector plates 72, which may cause the truss components to misalign. After installing the connector plates 72A, 72B, the press 71 returns to a position adjacent to the robotic arm 85 for receiving two more connectors 72A, 72B. The robotic arm 85, and associated hardware and software that can perform the functions as described herein, are commercially available through ABB Robotics and/or Nachi Robotics, model number VSO5E/LE-02.
These robotics contain programmable controllers and processors that control movement of the arm. The main controller 30 is linked to the robotic arm 85 to generate a signal indicative of an instruction for the robotic arm 85 to retrieve a connector plate 72 from the bin assembly 86. The controller 30, includes a database that represents the total number of connector plates 72 used to complete a particular job including the total number of each size connector plate 72, the order in which each connector plate 72 shall be retrieved from the bin assembly 86 and the coordinates (x,y,z) at which each connector plate 72 is located relative to an end of the robotic arm 85 and the ground. The controller 30 indexes or counts the connector plates 72 as they are retrieved from the bin assembly 86 in order to identify the subsequent plates 72 to be retrieved. The assembly of a truss 10 typically requires several different sizes of connector plates 72. For example, the smaller connector plates 72 may range in size from 3″×4″ to 6″×6″. Accordingly, several bins 166 may be arranged to account for different size connector plates 72.
Now referring to
In addition, to enable the bin assembly 86 to hold a large number of connector plates 72, yet make a small number of connector plates 72 available for simple pick up by the robotic arm 85, the bin assembly 86 includes a pushing assembly 180 for making two or more connector plates 72 readily available in the front tray portion 178 of a bin 166 for easy pickup of the connector plates 72 by the magnet 88 of the robotic arm 85. As shown in
The pneumatic cylinder 182 is operably connected to an actuating mechanism 188 disposed at the front tray portion 178 by two or more lines 190. As shown in
In addition, as shown in
When the controller 30 generates a signal indicative of an instruction for the robotic arm 85 to retrieve a connector plate 72 from the plate bin 86, robotic arm 85 first triggers the actuating mechanism 188 of a predetermined compartment of the plate bin 86 by contacting push-button 192 for a sufficient time so as to activate the actuating mechanism 188. As a result of activation of the actuating mechanism 188, air may be delivered to one of the two ports from a suitable compressed air source through air lines 190 to move the piston 184 in a forward direction. Since the piston 184 is secured to the engagement member 186, the piston 184 will cause the engagement member 186 to move from its resting position in a forward direction shown by arrow C in
Third station 16 includes an automated system 200 for presenting and positioning the web members 12 relative to the cord members 11A, 11B on the assembly table 20 in order from left to right, or from right to left. As shown in
The web presenter 90, shown in
With respect to
The second saw system 18 is linked with a controller 29 and is programmed to cut the web members 12 in the order in which the web members 12 are to be attached to the cord members 11A, 11B. The cut web members 12 exit a cutting zone of the second saw system 18 onto the linear conveyor 19B, which transports the web members 12 down the conveyor 19B. The system 18 includes a sensor 94 positioned toward an end of conveyor 19B. The sensor 94 detects the presence of a web member 12 on the conveyor 19B when a web member 12 reaches a predetermined distance from the sensor 94 or end of the conveyor 19B. When a web member 12 is detected a predetermined distance from the end of the conveyor 19B, the sensor 94 generates a signal indicative of the presence of a web member 12, which signal is received by the saw controller 29. The saw controller 29 is in communication with the motor and belt assembly 38 and signals the motor and belt assembly 38 to stop. At the same time, the sensor 94 conveys a signal to controller 30 or 104 for the robotic arm 90 to pick up the web member
The controller 31 is programmed to identify the particular web member 12 including the length of the web member 12. As explained above, each of the controllers is programmed to include a database that includes data representative and associated with each web member 12, including the dimensions of the web members 12 or cord members 11A, 11B, and the order in which the components are cut, staged and assembled. Accordingly, as the web members 12 are cut, staged and assembled, the controller 31 counts or identifies each web member 12 as it is staged and presented for assembly.
When the sensor 94 detects the web member 12, a signal is generated and sent to the controller 31. In tun, when the controller 31 receives the signal from the sensor 94, the controller 31 identifies the web member 12 including the length of the web member 12. The controller 31 is able to calculate the rate of speed the web member 12 is traveling on the conveyor 19B. Based on this calculation the controller 31, also having data relative to the length of the web member 12, determines the time at which the web presenter 90 will be activated to verify the identity of the web member 12, adjust a position of the web member if necessary, and present the web member 12 to the assembly table 20 for pickup by the robotic arm 101. The web member 12 is positioned on assembly table 20 such that the robotic arm 101 will pick up the web member 12 at a predetermined location of the web member 12 as will be discussed in detail below.
Prior to the robotic arm 101 engaging the web member 12, the web presenter 90 may perform functions that assure the web member 12 is positioned at the appropriate coordinates for presentation to the robotic arm 101. In an embodiment, as shown in
With respect to
First, the web presenter 90 grasps the web member 12 at or adjacent a center of the web member as shown in
Once the two leading edges 204, 206 for the left side of the board have been detected, the controller 31 causes the web presenter 90 to move rightward to likewise determine a first leading edge 208 and second leading edge 210 on the opposed right side 211 of the board. As shown in
From the information gathered by the sensors 107, 108, the controller 31 can verify that a length 212 of the web member 12 between the first leading edges 204, 208 and a length 214 between the second leading second leading edges 206, 210 match the data for the web member 12 in the controller 31. If so, the identity and length of a particular web member 12 is verified. If the gathered data does not verify the identity of the measured web member 12, a signal can be emitted from the controller to indicate that the controller 31 could not identify the web member at the front of the conveyor and appropriate action may be taken. For example, if the board does not have the proper dimensions, an operator stops the system to manually inspect the board. If the operator confirms that the dimensions are incorrect, the operator may manually cut the board to the correct dimensions. In addition, the operator may need to inspect other boards to determine the system 200 is cutting and presenting the boards in the proper order. Further, it is contemplated that depending on the orientation and cut of the board, some web members may not have more than one leading edge, which is detectable by the sensors 107, 108. In such case, only the first leading edge on each side of the board will be measured and that data utilized to determine the identity and length of the particular web member.
In one embodiment, the web presenter 90, after verifying the identity of the web member, places the web member 12 on the assembly table 20 as indicated in
To illustrate an exemplary board,
To further illustrate the above apparatus, system 200, and method for verifying the identity of a particular web member 12 and adjusting the position of the web member on the assembly table, a particular example is provided. In this example, the distance between the two sensors is 130 inches, for example. When the web presenter 90 grasps the web member 12, the web presenter 90 is generally positioned to grasp the web member 12 using suction platen 202 or the like at an approximate center of the board, i.e., a centerpoint (65 inches) between the two sensors. However, in this example, the web member 12 is grasped by the web presenter on the conveyor 19B slightly off center at for example 1 inch to the left of a center 216 between the leading edges 204, 208 of the board. Thus, there are 64 inches to reach left sensor 107. In this example also, the web member 12, prior to verification, is believed by the controller 31 to be a web member having a total length of 40 inches.
First, the controller 31 causes the web presenter 90 to move leftward a distance of 46 (65-19) inches before the sensor detects a first leading edge 204 of the web member. Thereafter, the web presenter 90 will continue to move the web member 12 leftward until the second leading edge 206 is detected, which may be another couple of inches, for example. Thus, when the second leading edge 206 is detected, the web presenter 90 will have moved a total of 48 inches to the left. Thereafter, the controller 31 will generate a signal to cause the web presenter 90 to move to the right.
Since the web presenter 90 grasped the web member 12 slightly off center, the web presenter 90 will continue to move the web member 12 rightward until the right sensor 108 detects the first right leading edge 208 of the web member 12, which if the board is a 40 inch board, will be at 92 inches (65 inches-21 inches (half the board plus one inch off center) plus 48 inches. Thereafter, the web presenter 90 will further move the web member 12 rightward such that the second leading edge 210 is detected, which may be, for example, another six inches to the right. The controller 31 now has all the information necessary to confirm the identity of the web member 12. When the identity of the web member 12 is verified, the controller 31 can also identify the fact that the web presenter 90 has grasped the board one inch off-center to the left and account for the same.
Having the data stored therein, the web presenter 90 will now compensate for the staple center 218 of the web member 12. The location of the staple center 218 is predetermined and the information is stored with the controller 31. If for example, the staple center 218 is two inches from the center 216, the web presenter 90, after compensating for the one inch off-center noted above, will move the web member 12 to the left two inches when placing the web member 12 on the assembly table 20 as shown in
Referring now to
Alternatively, instead of temporarily and/or permanently stapling two or more adjacent truss components together, such as cord members to cord members, web members to cord members, or web members to web members, the two or more truss components may be manually or automatically and temporarily and/or permanently secured to one another by applying an adhesive or taping the truss components together. If an automated adhesive dispenser or tape applicator is utilized, in one embodiment, the adhesive dispenser or tape applicator may be positioned at the same location on the robotic arm 101 as the staple guns 230 described above. Suitable adhesives, include, but are not limited to fast drying hot melt adhesives. If tape is used to secure two or more truss components together, the tape may be a double-sided foam tape available from 3M, for example. Alternatively, the adhesive or tape may be any other suitable adhesive or tape known in the art. Further, any suitable automated adhesive dispensing or tape application device known in the art may be utilized.
In one embodiment, the clamping devices 228 and staple guns 230 mounted on the second lever arm 226 are movable as a unit on a servomotor driven track 232, which is disposed on a base portion of the frame 234. The servomotor driven track 232 enables the lateral movement of the staple guns 230 and clamping devices 228 on the track 232 such that the clamping devices 228 can grasp a web member 12 from a position on the assembly table 20 adjacent the web presenter 90, place the web member 12 at its suitable position between cord members 11A, 11B, and the staple guns 230 can provide a staple to the truss 10 to at least temporarily secure a web member 12 to a cord member 11A, 11B. In one embodiment, the staple guns 230 are driven by contact such that when either of the staple guns 230 contact a web member 12 or cord member 11A, 11B, the staple gun or guns 230 automatically trigger to drive a staple into the web member 12 or cord member 11A, 11B.
In one embodiment, the clamping devices 228 include a first plate member 236 and a second plate member 238. The second plate member 238 is movable inward or outward relative to the first plate member 236 on a piston 240. In one embodiment, the second plate member 238 is movable inward or outward by way of a pneumatic cylinder 242 of the type set forth with respect to the pneumatic cylinder 186 above. The pneumatic cylinder may be of a double acting cylinder type, having two ports to allow air in, one for outstroke and one for instroke and the piston 240. The movement of the piston 240 allows the second plate member 238 to move inward or outward with respect to the first plate member 236 in response to any communication from the controller 31 that there is a web member 12 for the clamping device 228 to grab or release.
Once the web member 12 on the assembly table 20, the robotic arm 101 will pick up the web member 12 at the staple center 218 and will position the web member 12 for attachment to corresponding cord members. As shown in
The robotic arm 101 may be programmed to distinguish web members 12 from one another. The robotic arm 101 is programmed to retrieve each web member 12 at a particular location having an x,y,z coordinates relative to the end of the robotic am 101 and ground. In one embodiment, the web presenter 90 positions the staple center 218 of each web member 12 at that location. Similarly, the robotic arm 101 is programmed to position the staple center 218 of the web member at the above-mentioned predetermined positions which have x,y,z coordinates relative to the end of the robotic arm 101 and the ground. The controller 30 and components of the assembly table (clamping devices, roller guides etc.) are programmed to advance the truss 10 on table 20 to a position so the web member 12 fits between and abuts the inside edges of the cord members 11A, 11B.
When the robotic arm 101 has retrieved the web member 12 as described above, the controller 30 or 104 generates one or more signals responsive to which the robotic arm 101 moves on a gantry 120 and/or rotates to grab the web member 12. The robotic am 101 then places the staple center 218 (not shown here) of web member 12 at a first predetermined location that so the ends of the web member 12 are displaced to the left of the cord members 11A, 11B. The robotic arm 101 then moves the center 218 of the web member 12 to the right so that each end of the web member 12 abuts an inside edge of a respective cord member 11A, 11B as shown in
The controller 30 or 104 is in electrical communication with a processor of the robotic arm 101, to determine when the web member 12 is appropriately positioned for attachment to the cord members 11A, 11B. At that time, the controller 30 or 104 generates one or more signals, responsive to which staple guns 230A, 230B move across the table 20 to staple the web member 12 to the cord members 11A, 11B. The controller 30 or 104 monitors the movement of a servo-driver (not shown) connected to the staple gun 230A or 230B so the controller 30 is able to determine when the staple guns 230A, 230B (and the presses 71A, 71B described above) return to a home position, so the truss 10 may be advanced on the table 20.
Typically, the truss 10 is thereafter advanced on the table 20 a sufficient distance so the points at which the web member 12 abut the inside edges of the cord members 11A, 11B, are aligned with the presses 71A, 71B. In this manner, the presses 71A, 71B, responsive to one or more signals from the main controller 30, move on I-beam 144 to press connector plates 72 onto the truss, thereby securing the web member 12 to the cord members 11A, 11B as described previously herein. As the presses 71A, 71B are moving and/or stamping the connector plates 72 on the truss 10, the robotic arm 101 is retrieving a second web member 12 and placing it in position relative to the cord members 11A, 11B for assembly of the truss 10. These steps are repeated for all the web members 12 for a particular truss until the truss 10 is fully assembled.
As shown in
In addition, the main press 39 may include one or more pneumatic cylinders, including one of the type described with respect to presses 71A, 71B to separate any two connector plates 72 when the two connector plates are placed on a lower platen 246. Further, the pneumatic cylinder may aid in retracting the platens 244, 246 after the connector plates 72 are pressed onto a particular truss 10. In one embodiment, the pneumatic cylinder is embedded in the upper platen 244 and the upper platen includes a magnet (not shown) to aid separating any two connector plates that are placed on the lower platen 246.
In one embodiment, the clearance space 252 between the upper platen 244 and the lower platen 246 when the press 39 is in an idle position is relatively small, i.e., about three inches. In this way, when the platens 244, 246 are moved toward one another to press a large connector plate on a portion of the truss 10, the truss and/or connector plate is not bent, crushed, twisted, or otherwise damaged.
The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
This application claims benefit under 35 U.S.C. §119(e)(1) of the Jan. 23, 2007, filing date of U.S. Provisional Application No. 60/886,147, the entirety of which is incorporated by reference herein.
Number | Date | Country | |
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60886147 | Jan 2007 | US |