Information
-
Patent Grant
-
6612230
-
Patent Number
6,612,230
-
Date Filed
Tuesday, October 10, 200023 years ago
-
Date Issued
Tuesday, September 2, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Ostrager; Allen
- Nguyen; Jimmy
Agents
-
CPC
-
US Classifications
Field of Search
US
- 100 35
- 100 913
- 100 160
- 100 161
- 100 155
- 100 168
- 100 DIG 13
- 100 100
- 100 210
- 100 176
- 269 296
- 269 303
- 269 910
-
International Classifications
-
Abstract
In accordance with the principles and concepts of the invention, apparatus and methods for assembling pre-cut members into trusses and joists and splicing pre-cut members into truss chords are presented. According to the invention, a splicing apparatus for connecting chord members end-to-end comprises a table having a table surface for supporting abutting chord members, a gantry press mounted adjacent to the table surface and configured to move relative to the table surface, the gantry press having at least two press rollers, each press roller having a peripheral surface positioned a successively closer clearance distance to the table surface. The splicing apparatus may further comprise at least two abutting chord members supported on the table surface, the chord members forming end-joints at each abutment and at least one connector plate positioned above each end-joint whereby each of the press rollers presses the connector plates at least partially into the chord members as the gantry press moves relative to the table surface. The apparatus may further comprise at least one connector plate positioned below each end-joint. The press rollers may be adjustable whereby the clearance distances of the peripheral surfaces of the press rollers above the table surface can be adjusted. The splicing apparatus may also comprise a truss assembly table.The chord members are spliced together, end-to-end, by placing multiple wooden chord members in end-to-end abutment on the table surface, the chord members having end-joints at each end-to-end abutment, placing at least one connector plate over each end-joint, and pressing the connector plates into the chord members with a gantry press supported above the table surface and configured for movement relative to the table surface. The gantry press has a plurality of press rollers, each press roller having a peripheral surface positioned successively closer to the table surface, each press roller incrementally pressing the at least one connector plate into the chord members. The method may further comprise placing at least one connector plate under each end-joint between chord members. The clearance distances of the press roller peripheral surfaces may be adjusted.
Description
TECHNICAL FIELD
The present invention relates in general to an apparatus and method for fabricating structural components. More particularly, this invention concerns an apparatus and method for assembling pre-cut members into trusses and joists and splicing pre-cut members into truss chords.
BACKGROUND OF INVENTION
Prefabricated trusses for use as roof or floor supports are assembled from pre-cut wooden chord and web members positioned in abutting relationship and connected together using toothed fastener plates. Where the length of the desired truss exceeds the length of readily available wood members, it is necessary to splice, or connect, multiple members in end-to-end abutment to create a single expanse of wooden chord.
Separate truss assembly and splicing devices have been developed for performing these tasks semi-automatically. In a truss assembly device, the pre-cut wooden members are positioned manually over a rigid support surface, then jigged or clamped in place. Connector plates then are laid over the abutting joints of the wooden members. The connector plates are then embedded into the members with a gantry or other roller press to secure the joints on one side. The gantry press typically has a single roller which passes over the truss assembly, thereby squeezing the truss assembly between the table surface and the roller. The semi-complete truss is then turned over and similarly secured at the joints on the opposite side with another set of connector plates. The gantry roller and truss table are shown in detail in U.S. Pat. Nos. 5,211,108 and 4,084,498 and in co-pending application Ser. No. 09/416,862, filed Oct. 13, 1999 by David McAdoo and Michael Rosser, the disclosure of which is incorporated herein by reference for all purposes.
In a typical splicing device, two wooden members are joined together in end-to-end abutment. Splicing of wooden members using a gantry press table having a single roller passing over a rigid table surface has been unsatisfactory, resulting in bowed, bent or cambered spliced chords, as shown in
FIGS. 1 and 2
. Chord members
2
, spliced together at end-joint
8
on table surface
4
by gantry roller
9
, are held together by connector plates
6
. After the plates
6
are pressed into the chords
2
, the spliced chords exhibit an undesirable bow, as seen in FIG.
2
.
Typically, splicing and truss assembly operations occur on separate machines. Chord members are spliced together in one location within a facility, then laboriously moved to a truss assembly device where they are incorporated into a truss assembly. This process requires time, space and labor.
There exists a need for a new and improved truss assembly and splicing apparatus.
SUMMARY OF THE INVENTION
In accordance with the principles and concepts of the invention, apparatus and methods for assembling pre-cut members into trusses and joists and splicing pre-cut members into truss chords are presented. According to the invention, a splicing apparatus for connecting chord members end-to-end comprises a table having a table surface for supporting abutting chord members, a gantry press mounted adjacent to the table surface and configured to move relative to the table surface, the gantry press having at least two press rollers, each press roller having a peripheral surface positioned a successively closer clearance distance to the table surface. The splicing apparatus may further comprise at least two abutting chord members supported on the table surface, the chord members forming end-joints at each abutment and at least one connector plate positioned above each end-joint whereby each of the press rollers presses the connector plates at least partially into the chord members as the gantry press moves relative to the table surface. The apparatus may further comprise at least one connector plate positioned below each end-joint. The press rollers may be adjustable whereby the clearance distances of the peripheral surfaces of the press rollers above the table surface can be adjusted. The splicing apparatus may also comprise a truss assembly table.
The chord members are spliced together, end-to-end, by placing multiple wooden chord members in end-to-end abutment on the table surface, the chord members having end-joints at each end-to-end abutment, placing at least one connector plate over each end-joint, and pressing the connector plates into the chord members with a gantry press supported above the table surface and configured for movement relative to the table surface. The gantry press has a plurality of press rollers, each press roller having a peripheral surface positioned successively closer to the table surface, each press roller incrementally pressing the at least one connector plate into the chord members. The method may further comprise placing at least one connector plate under each end-joint between chord members. The clearance distances of the press roller peripheral surfaces may be adjusted.
Further according to the invention is presented a truss assembly and chord splicing apparatus combination having a table with a truss assembly surface for supporting a truss assembly, a splicing surface for supporting abutting chord members and a gantry press assembly mounted adjacent to the table and configured to move relative to the table, the gantry press assembly having a primary press roller configured to move over the truss assembly surface and at least two splicing press rollers configured to move over the splicing surface, the at least two splicing press rollers each having a peripheral surface positioned successively closer clearance distances above the splicing surface. The truss assembly may also have a plurality of abutting truss members positioned on the truss assembly surface forming truss joints at each abutment and abutting chord members supported on the splicing surface, the chord members forming end-joints at each abutment. A connector plate is positioned above each joint. Connector plates may be positioned under the chord joints. The primary press roller may further be configured to move over the splicing surface. The truss assembly surface and the splicing surface may be different heights above a floor surface.
Further is presented a truss assembly and chord splicing apparatus comprising a truss assembly table having a truss assembly surface and a splicing surface with a gantry press having a primary press roller and a splicing subassembly, the subassembly comprising at least two splicing press rollers, the splicing press rollers each having a peripheral surface positioned a successively closer clearance distance above the splicing surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Drawings of a preferred embodiment of the invention are annexed hereto, so that the invention may be better and more fully understood, in which:
FIG. 1
is an elevational schematic view of a typical prior art splicing apparatus;
FIG. 2
is an elevational schematic view of a typical prior art spliced chord member;
FIG. 3
is a perspective view of a truss assembly apparatus of the invention shown without attached splicer subassembly for clarity;
FIG. 4
is a top plan view of a truss assembly apparatus of the invention shown without attached splicer subassembly for clarity;
FIG. 5
is a top plan view of a truss assembly apparatus of the invention with clamping assemblies actuated;
FIG. 6
is an elevational sectional view of a truss table of the invention with clamping assemblies taken along line
6
—
6
of
FIG. 3
;
FIG. 7
is an elevational sectional view of a truss table of the invention with trusses clamped by the clamping assemblies;
FIG. 8
is an elevational sectional view of a truss table of the invention with a truss movement assembly taken along line
8
—
8
of
FIG. 3
;
FIG. 9
is an elevational sectional view of a truss table of the invention with a truss movement assembly with the flip-over assembly actuated;
FIG. 10
is an elevational sectional view of a truss table of the invention with a truss movement assembly with the lift-out assembly actuated;
FIG. 11
is an isometric partial view of a truss assembly table with splicing subassembly of the present invention;
FIG. 12
is an elevational partial view of a truss assembly table with splicing subassembly of the present invention;
FIG. 13
is a sectional view of
FIG. 12
;
FIG. 14
is an isometric view detail of the splicing subassembly;
FIG. 15
is an end view detail of the splicing subassembly; and
FIG. 16
is a schematic detail of the splice and gantry rollers in relation to the splice work surface.
Numeral references are employed to designate like parts throughout the various figures of the drawing. Terms such as Aleft, @ Aright, @ Aclockwise, @ Acounter-clockwise, @ Ahorizontal, @ Avertical, @ Aup@ and Adown@ when used in reference to the drawings, generally refer to orientation of the parts in the illustrated embodiment and not necessarily during use. The terms used herein are meant only to refer to relative positions and/or orientations, for convenience, and are not to be understood to be in any manner otherwise limiting. Further, dimensions specified herein are intended to provide examples and should not be considered limiting.
DESCRIPTION OF A PREFERRED EMBODIMENT
The invention is herein described with reference to the accompanying drawings and is not intended to limit the scope of the claimed invention, but is intended to describe particular embodiments to disclose the best mode of the invention to those skilled in the art.
Truss Assembly Apparatus:
FIGS. 3-5
show a truss assembly apparatus
10
for semi-automatic manufacture of prefabricated structural components, particularly wooden trusses and joists. The truss assembly apparatus
10
comprises a truss table
12
and a table gantry press
14
supported on the table for movement therealong.
The work surface
16
of the truss table
12
is defined by table plates
18
a-j
, which are arranged end-to-end. Table plates
18
b-i
provide working space for assembly of the trusses
20
and
22
, while plates
18
a
and
18
j
provide staging areas for the table gantry press
14
. The table may be designed to any desired length. The plates
18
are supported by a plurality of cross-members
24
which are mounted to the legs
26
of the table. Each leg
26
of the table
12
preferably includes a foot
28
threadedly attached thereto for height adjustment and leveling of the truss table
12
(best seen in FIG.
3
). Side beams
30
extend longitudinally beneath the table plates
18
. Outer rails
32
extend longitudinally above the table work surface
16
along the outer edges of the table plates
18
. Clamping assemblies
50
are attached to the table
12
, as shown.
The table gantry press
14
straddles the work surface
16
of the truss table
12
and is supported to run along the length of the table. Gantry wheels
34
, located in the gantry arms
36
, roll along the gantry tracks
38
, which are mounted to the truss table
12
. A primary roller press
140
(shown in
FIG. 13
) located in the gantry body
40
presses downwardly on the truss table
12
as the gantry press
14
passes along the table length.
Referring to
FIGS. 4 and 5
, truss table
12
is divided into three longitudinal zones A, B, and C by the clamping assemblies
50
. In the preferred embodiment, two clamping assemblies
50
are mounted on each of the support plates
18
. Assembly zones A and C on each plate
18
are coincident with the inner and outer jigs
52
and
54
of the clamping assemblies
50
. Intermediate zone B extends between the clamping assemblies
50
and may be reduced to zero area when the clamping assemblies
50
are not actuated to clamp a truss, such as trusses
20
and
22
, as seen in FIG.
4
and as will hereinafter be described. During operation of the truss assembly apparatus
10
, precut truss chords
42
and webs
44
are manually placed in a first truss position
21
with a first truss face
25
contacting the table surface in zone A and are secured in place by the clamping assembly
50
. Toothed connector plates
46
, which may be stored in the recessed areas
48
between the outer rails
32
and the outer longitudinal jigs
52
, are then placed over the joints between the truss members
42
and
44
(as seen in
FIGS. 6 and 7
) and subsequently embedded in place by passage of the gantry press
14
over the truss
20
. The semi-finished truss
20
is then unclamped, rotated along its longitudinal axis L, and placed in zone C so that the embedded connector plates
46
are positioned downwardly. The semi-finished truss
20
, now in the second truss position
23
, the location of truss
22
in
FIG. 4
, with a second truss face
27
contacting the table surface is clamped in place by the clamping assembly
50
and secured at the joints on the now upwardly facing side of the truss
22
with connector plates
46
embedded therein by another passage of the gantry press
14
. The now completed truss
22
is unclamped, removed from zone C, and moved off of the truss table
12
for storage. During typical use of the truss assembly apparatus
10
, connector plates
46
are pressed into trusses
20
and
22
in both zones A and C during a single passage of the gantry press
14
.
Two clamping assemblies
50
are mounted on each plate
18
, as shown in
FIGS. 3 and 4
. The details of the clamping assemblies
50
are best illustrated in
FIGS. 6 and 7
. Each clamping assembly
50
includes an inner longitudinal jig
52
and an outer longitudinal camber inducing rail or jig
54
each of which may be divided into a plurality of longitudinally spaced jigs, as shown. The jigs
52
and
54
maybe of angle irons oriented as shown. The outer jigs
54
are attached to the working surface
16
of the truss table
12
. Preferably the outer jigs are bolted, or otherwise removably attached, to allow reconfiguration of the jigs as desired. The inner jigs
52
are slidably mounted to the truss table
12
. In the preferred embodiment, each of the inner jigs
52
are mounted to a truck assembly
56
including an upper jig truck
58
which is supplied with truck wheels
60
. The upper truck
58
is connected, such as with truck spacers
62
, to a lower jig truck
64
which is similarly supplied with wheels
60
. The jig trucks
58
and
64
straddle the clamping slot
66
and the wheels
60
allow the trucks
58
and
64
to roll along the upper and lower surfaces of the table plates
18
, respectively. The truck spacers
62
extend through clamping slot
66
which is formed in the table plate
18
in a transverse direction across the truss table
12
as best seen in
FIGS. 3 and 4
. Other methods of slidable mountings, such as friction mountings, may be used without departing from the spirit of the invention. The jig trucks
58
and
64
are attached to a jig actuator, such as the air cylinder
68
shown. Other actuators may be employed, and may be mounted above or below the table surface, although the actuator design illustrated is preferred for reasons hereinafter explained. The air cylinders
68
are mounted under the surface of the table plates
18
by jig actuator brackets. The extendable air cylinder jig rods
72
are connected to the truck assemblies
58
and
64
.
Turning to the clamping assembly in zone A, when the air cylinder
68
is in a retracted position, as in
FIGS. 4 and 6
, the inner jig
52
is positioned near the center of the truss table
12
in a home position
74
as shown. As the air cylinder
68
is actuated, the rod
72
extends outwardly, moving the truck assembly
56
, which in turn moves the inner jig
52
, across the truss table
12
along the clamping slot
66
toward the outer jig
54
to an extended or clamped position
76
, as seen in FIG.
5
. The air cylinder
68
will extend to its full length or until the inner jig
52
encounters and clamps truss into place in zone A. Similarly, a truss
22
in zone C may be clamped in place by actuation of the air cylinder
68
, of the clamping assembly in zone C which will move the truck assembly
56
and inner jig
52
toward outer jig
54
. The trusses
20
and
22
are unclamped after the gantry press
14
has embedded the connector plates
46
into the truss by retraction of the air cylinder to their retracted position, seen in FIG.
4
.
Referring back to
FIG. 4
, each inner jig
52
is preferably activated independently with a corresponding air cylinder
68
. The clamping assemblies
50
act in unison to hold the trusses
20
and
22
in place. Where inner jigs
52
do not encounter a truss, they are extended as far as the air cylinder
68
will allow. One of the advantages in having a plurality of clamping assemblies
50
each with a separate inner jig
52
acting on a single truss
20
as explained herein. Floor trusses, such as those seen in
FIGS. 3-5
, have parallel top and bottom chords
42
. In low-slope roofing applications, however, the members
42
are not parallel. Sloped chord trusses can be assembled.in the present truss assembly apparatus
10
because the plurality of clamping assemblies
50
will contact the sloping member
43
at more than one point on the truss, or along its entire length, as shown. A single longitudinal inner jig
52
which ran the length of the table, such as is common, would only contact the sloped member
43
at a single location. The inner jigs
52
of the invention may be pivotally attached to the jig trucks
58
, if desired, to allow for contact between the jigs and truss members with greater slopes.
Once the gantry press
14
has embedded the connector plates
46
into the trusses in zones A and C, the truss in zone C must be lifted out and removed from the table. The truss in zone A must be lifted out, turned over and placed in zone C for completion of the fabrication.
Movement of the trusses is accomplished with the truss movement assembly
80
, seen in
FIGS. 8-10
, which comprises a flip-over assembly
82
and a lift-out assembly
100
.
The flip-over assembly
82
is located adjacent zone A and is attached to the lower surface of the truss table
12
by the truss movement assembly bracket
84
. The flip-over assembly
82
comprises an elongate flip-over arm
86
which is connected at one end by a flip-over arm pivot mounting
88
to the movement assembly bracket
84
adjacent the lower surface of the table
12
. A flip-over arm bracket
90
pivotally connects the flip-over arm
86
at a point removed from the flip-over pivot mounting
88
to one end of the flip-over actuator
92
. In the preferred embodiment, the flip-over actuator is an air cylinder
92
having one end pivotally connected to the movement assembly bracket
84
and the rod end
94
connected to the flip-over arm bracket
90
.
While the truss
20
is being assembled and pressed, the flip-over assembly
82
is in a home position
87
, as seen in
FIG. 10
, wherein the flip-over arm
86
is positioned not to interfere with assembly of the truss
20
. The flip-over arm
86
is pivoted to the extended position
89
, seen in
FIG. 9
, by the extension of the rod
94
of the air cylinder
92
. The flip-over arm passes through assembly slot
78
to contact the truss
20
. The flip-over arm
86
and actuator are arranged such that the flip-over arm rotates through and preferably past the vertical plane V so that the truss
20
is rotated longitudinally before falling from the flip-over arm
86
into zone C. Preferably, at least the end
91
of arm
86
moves to a position over zone C, as shown in FIG.
9
. The motion and extended position
89
of the flip-over arm
86
thus lifts the truss
20
from zone A, rotates and deposits it such that the connector plates applied to the truss face downwardly in zone C.
Prior to the actuation of the flip-over arm
86
, the movable inner jigs
52
are brought to their home position at the center of the table. With the inner jigs so arranged, abutting one another, the area of zone B, evident when the braces are clamping the trusses as in
FIG. 7
, is reduced greatly, or preferably completely, as in FIG.
8
. Many truss assembly mechanisms are unable to greatly reduce or eliminate the area of zone B because of the jig mechanisms disposed in the intermediate zone. The present invention eliminates the area of zone B by mounting the clamping assembly actuators below the table surface and moving the jigs via the small jig trucks actuated through the clamping slots. Because of this feature, the flip-over arm is designed to deposit the truss directly to zone C. In prior art inventions the truss is deposited at least partially into zone B requiring manual relocation of the truss into zone C for further assembly.
The lift-out assembly
100
is positioned adjacent zone C and is attached to the truss movement assembly bracket
84
which is mounted to the table
12
below the work surface
16
as shown. The lift-out assembly
100
comprises a lift-out arm
102
and a lift-out actuator assembly
104
. The lift-out arm
102
is seen in its home position
103
in
FIG. 8
, wherein the lift-out arm
102
does not interfere with assembly of the truss
22
. After completion of assembly of the truss
22
the lift-out actuator assembly
104
is activated to raise the lift-out arm
102
and move it laterally towards the outer rail
32
at the edge of the table
12
into the extended or finished position
105
seen in FIG.
10
. The lift-out arm
102
acts on the truss
22
after passing from below the table surface
16
to above the table surface through assembly slot
78
. The lift-out arm
102
in turn moves the truss
22
to a position out of zone C and toward the table edge for removal to a conveyor assembly or to storage. The lift-out arm
102
is designed to raise the truss
22
above the outer rail
32
. Also, the lift-out arm
102
is preferably designed such that in the extended position the lift-out arm
102
extends slightly past the outer rails
32
of the table for ease of removal of the truss from the table.
The lift-out actuator assembly
100
, in the preferred embodiment, comprises a lift-out actuator, such as the air cylinder
106
, pivotally connected at one end to the movement assembly bracket
84
and pivotally attached at the other end to the lift-out power arm
108
. In the preferred embodiment, the actuator is an air cylinder, but other actuating devices may be employed. The rod end
110
of the air cylinder
106
is pivotally attached to the lift-out power arm
108
through the cylinder bracket
112
. The lift-out power arm
108
is pivotally mounted to the movement bracket
84
at one end and pivotally attached to the lift-out arm
102
at the other end through the power arm bracket
114
. Similarly, the support arm
116
is pivotally connected to the movement assembly bracket
84
at one end and to the lift-out arm
102
at the other end through a support arm bracket
118
. When the air cylinder
106
is actuated, the rod end
110
extends outwardly, pivoting the power arm
108
which in turn lifts and laterally moves the lift-out arm
102
. The support arm
116
acts to raise and laterally move the lift-out arm in conjunction with the power arm to the extended position. Actuator assemblies other than the described system may be used without departing from the spirit of the invention.
Preferably, the lift-out arm
102
has a plurality of rollers
120
connected thereto to assist the user in moving the truss
22
off of the lift-out arm
102
. The lift-out arm
102
also preferably has a stop block
122
attached to the lift-out arm
102
at its innermost end. The stop block
122
prevents the truss from rolling from the rollers
120
onto the truss table
12
.
The truss assembly apparatus described herein is preferably for use in fabricating wooden trusses and joists, although non-wooden members may be used as well.
Splicing Apparatus:
A truss assembly apparatus
10
with splicing subassembly
130
is shown in
FIGS. 11-17
.
FIG. 11
is an isometric view of a partial truss assembly apparatus
10
with splicing subassembly
130
.
FIG. 12
is an elevational view of a partial truss assembly apparatus
10
with splicing subassembly
130
.
FIG. 13
shows the same elevational view in cross-section. The clamping assemblies
50
and truss assemblies
20
and
22
are removed for clarity.
In
FIGS. 11-16
, the table gantry press
14
straddles the work surface
16
of the truss table
12
and is supported to run along the length of the table. A primary roller press
140
, seen in
FIG. 13
, located in the gantry body
40
presses downwardly on the truss table
12
as the gantry press
14
passes along the table length. Safety stop bars
132
provide for an automatic power cut to the apparatus should they be tripped during operation.
Truss assembly table
12
has a splice assembly area
134
along one longitudinal edge of the table, inside outer rail
32
. When the truss assembly table
12
is in use without the splicing subassembly
130
attached to the gantry press
14
, splice assembly area
134
serves as recessed area
48
for temporary storage of connector plates prior to placement on a truss assembly
20
as explained above. Splice assembly area
134
supports chord members
136
in end-to-end abutment on splice work surface
152
. Each chord
136
is supported longitudinally along assembly area
134
along a chord bottom surface
170
(seen in FIG.
13
). Each chord top surface
176
is seen in FIG.
11
. Adjacent chord end surfaces
172
abut at end-joint
8
. Chord members in
FIGS. 1 and 2
have been similarly numbered for clarity. Multiple chord members may be placed longitudinally in the splice assembly area in end-to-end arrangement to create a final spliced chord of any desired length. Connector plates
138
are placed above and below end-joint
8
. Connector plates
138
are pressed into the chord members
136
by roller presses as the splicing subassembly
130
and gantry press
14
pass along the table length as will be explained in further detail.
The splice assembly area
134
is preferably adjacent to truss assembly zone A. In this arrangement, during a single pass of the gantry press
14
and splicing subassembly
130
, chord members
136
are spliced together in splice area
134
while connector plates are pressed into a truss assembly in zone A as explained above.
Splice assembly area
134
is defined by the splice jig assembly
150
, seen best in
FIGS. 11 and 15
. Splice plate
151
is supported above truss table surface
16
by jig spacers
154
. Splice plate
151
supports the chord members
136
along splice work surface
152
. Jig spacers
154
can be formed of metal tubing and angle iron, as shown in detail in
FIG. 15
, or any other suitable material. Chord members
136
are maintained in a stationary position during the pressing process by jig end-stops
156
. The chord end surface
172
abuts jig end-stop
156
to prevent longitudinal movement of the chord members during the pressing process. Jig end-stops
156
can be adjusted longitudinally by sliding the stop along end-stop slot
158
. The end-stop
156
is fixed in place by tightening end-stop nut-and-bolt assembly
160
. A corresponding end-stop assembly can be affixed to the splice plate
151
at the opposite end of the splice assembly area (not shown). Typically only one end-stop is in use during a single pass of the gantry press and splicing subassembly. Since the gantry and splicer are arranged to press connector plates during passes in either direction, however, a jig end-stop is necessary on either end of the splice work area. The longitudinal edges of the chord members can be placed in abutment against the splice jig rail
162
to ensure the spliced chord members remain straight during the pressing process.
FIG. 15
is an end elevational view detail of the splice jig assembly
150
and splicing subassembly
130
. The depth D of splice assembly area can be adjusted by selecting the size of spacers
154
. Typically, depth D of the splice area is selected to accommodate a “two-by-four” chord member oriented with the “four-inch” bottom surface facing splice work surface
152
. Those skilled in the art will recognize that “two-by-fours” do not actually measure two inches by four inches (5.08 cm by 10.16 cm). The spacing of the jig assembly parts will vary according to the actual dimensions of the chord members. The working depth of the truss assembly area, on the other hand, is typically selected to accommodate “two-by-fours” oriented with the “two-inch” surface face down in the truss assembly zone A. The difference in orientation of the splicing chord members and the truss assembly members necessitates the splice jig assembly. The working width W, seen in
FIG. 11
, of the splicing area
34
can be selected to accommodate two or more chord members side-by-side if desired, as shown in FIG.
15
. In this manner, multiple spliced truss chords
42
can be spliced during a single pass of the gantry press
14
and splicer
130
.
FIG. 14
is a detailed isometric view of the splicing subassembly
130
.
FIG. 15
is a detailed view of the subassembly. Splicing subassembly
130
is mounted to the gantry body
40
via mounting plate
180
. The mounting plate
180
has multiple mounting slots
182
through which nut-and-bolt assemblies
184
(seen in FIG.
12
), extending from the gantry body
40
, are arranged. The slots
182
allow the splicing subassembly
130
to be adjusted vertically on gantry press body
40
by sliding the mounting plate
180
along slots
182
. The plate
180
is fixed in place by tightening the nut-and-bolt assembly
184
. An identical, but reverse oriented, splicing subassembly can be mounted on the opposite side of the gantry press body
40
, as seen in FIG.
12
. This allows the user to splice chord members as the gantry press
14
and splicers
130
move in either direction along the truss table
12
.
Splicing subassembly splice rollers
190
,
192
,
194
and
196
are mounted on support arms
198
. Splice rollers
190
,
192
,
194
and
196
have cylindrical roller peripheral surfaces
200
,
202
,
204
and
206
, respectively, for contacting the connector plates
138
, and each splice roller rotates about its respective roller axes X. Splicing subassembly adjustment arms
208
are pivotally mounted to mounting plate
180
at one end and pivotally mounted to end-plate
210
at the opposite end. Adjustment arms
208
can preferably be shortened or lengthened by turning reverse-threaded tubing attached to reverse-threaded bolts located at either end of the adjustment arms. Adjustment of the length of arms
208
correspondingly adjust the positions of splice rollers
190
,
192
,
194
and
196
. Other methods of adjustment will be readily recognized by those skilled in the mechanical arts.
The splice subassembly supports the splice rollers
190
,
192
,
194
and
196
at successively smaller distances above the splice work surface
152
. As shown best in
FIG. 16
, each splice roller peripheral surface
200
,
202
,
204
and
206
, at the point closest to the work surface
152
, is spaced a clearance distance
220
,
222
,
224
and
226
, respectively, above the work surface
152
. The clearance distances
220
,
222
,
224
and
226
can be adjusted by adjusting the mounting plate
180
along slots
182
and by adjusting the length of the adjustment arms
208
. The clearances are selected such that each roller incrementally presses connector plates
138
into the chords
136
. Preferably, both the top and bottom connector plates
138
are pressed into the chord members by the splice rollers and primary gantry roller
140
. It is not necessary to place connector plates both above and below end-joints
8
, but it is preferred.
Preferably the splice roller clearance distances are spaced {fraction (1/16)}th of an inch (0.159 cm) apart. That is, the second splice roller
192
to pass over the connector plates and chord members has a clearance distance
222
which is {fraction (1/16)}th of an inch (0.159 cm) closer to the splice work surface
152
than the clearance distance
220
of the first splice roller
190
to pass over the connector plate. Similarly, each successive roller to pass over the chord members and connector plates is preferably {fraction (1/16)}th of an inch (0.159 cm) closer to the work surface
152
. The primary roller
140
of the gantry press also acts upon the connector plates and has a peripheral surface
230
and a corresponding clearance distance
228
. The primary roller
140
acts a last splice roller and presses the connector plates a last incremental distance into the chords. Preferably the clearance distance
228
of the primary roller
140
is ⅛th of an inch closer to the work surface
152
than the clearance distance
226
of the splice roller
196
which is closest to the work surface
152
. The clearance distances may vary from those listed and not depart from the spirit of the invention. The clearance distances above the work surface will vary depending upon the application and the dimensions of the chord members and connector plates selected.
The successively closer splice rollers and primary roller each incrementally advance the connector plates into the wooden chord members. The gradual pressing of the connector plates into the chord members by the passing of the plurality of rollers eliminates the bow or bend often present in spliced chords of the prior art.
Each splice roller
190
,
192
,
194
and
196
has a radius R and rotates about an axis X. Preferably the axes X are parallel as shown and the radii R are equal for the rollers. The rollers may be of differing radii. For example, each of the splice rollers and the primary gantry roller
140
acts upon the connector plates
138
to press the plates into the chord members
136
even though the gantry press roller
140
has a much greater radius than the splice rollers.
An alternate arrangement of the splicing subassembly is shown in FIG.
13
. The splicing subassembly can be supported either entirely outside of gantry body
40
, as shown on the right side of the Figure, entirely inside of gantry body
40
(not shown) or both inside and outside of gantry body
40
, as shown on the left side of the Figure. Further, the splicer can have a greater number of rollers (such as the six shown on the left side of
FIG. 13
) or lesser number of rollers than illustrated.
Method of Use:
In utilizing the splicing subassembly
130
, precut chord members
136
are placed in end-to-end abutment in splice assembly area
134
. One end surface
172
of chord
136
preferably abuts end stop
156
to prevent longitudinal movement of the chords
136
during pressing operations. The longitudinal edges of the chords preferably abut outer rail
32
. At least one connector plate
138
is placed over each end-joint
8
. Preferably connector plates are likewise place below each end-joint
8
. The splice rollers
190
,
192
,
194
and
196
, can be adjusted using the mounting slots
182
and adjustment arms
208
to position the peripheral surfaces
200
,
202
,
204
and
206
above the work surface
152
at respective clearance distances
220
,
222
,
224
and
226
. The clearance distances are selected such that each roller successively presses the connector plates an incremental distance into the chord members. Similarly, the primary press roller
140
can be adjusted to incrementally press the connector plates into the chord members. Preferably, each roller presses the connector plates into the chord members no more than ⅛th of an inch (0.318 cm). The gantry press
14
and attached splicing subassembly
130
are moved relative to the work surface
152
over the chord members
136
and connector plates
138
. As the gantry press and splicing subassembly pass over the chords, the plates are pressed into the chord members incrementally. After the gantry has passed the work area
134
, the now spliced chord members can be moved to the truss assembly area to be utilized in a truss assembly.
In utilizing the truss assembly apparatus
10
, precut wooden truss members
42
and
44
are arranged in zone A of the truss table
12
on the working surface
16
. Simultaneously, a semi-finished truss
22
is positioned in zone C. The clamping assemblies
50
are actuated, moving the inner jigs
52
outward toward the outer jigs
54
and clamping the trusses
20
and
22
between the jigs. End stops and other devices known in the art may be added to assist in the proper arrangement of the truss members. Connector plates
46
are placed over the joints between the truss members in both zones A and C and are usually manually tapped into the wood so that they will hold their positions during pressing. The gantry press
14
moves along the length of the table embedding the connector plates
46
into the wood. The clamping assemblies
50
are returned to their original home positions
74
such that the jigs are no longer clamping the trusses. In the home positions, the clamping assemblies preferably have little or no space between them in zone B, at the center of the table. This is, in part, accomplished by positioning the jig actuators
68
below the table surface
16
. The lift-out assemblies
100
are then actuated to move the lift-out arms
102
into extended positions
105
, that is, to move the lift-out arms upwardly through the assembly slots
78
from below the table surface
16
and engage the truss
22
thereby raising it out of zone C and moving it toward the outer rails
32
of the table. Preferably the lift-out arm
102
include rollers
120
and move in the extended position
105
to extend over the outer rails
32
for ease of removal of the truss
22
from the truss table
12
. The lift-out arm
102
may also include stop blocks
122
to prevent the truss
22
from rolling off the lift-out arms
102
the wrong direction. The lift-out out arms
102
are lowered back into position under the table surface
16
. The flip-over assemblies
82
are then activated. The flip-over arms
86
are rotated from a home position
74
under the table surface to an extended position
76
, engaging the truss
20
and lifting it from zone A while simultaneously rotating it along its longitudinal axis L. The flip-over arms
86
deposit the truss
20
in zone C with the connector plates
46
facing downward. The flip-over arms
86
are then returned to their home positions
74
. The order of the steps may vary without departing from the spirit of the invention. The process may be repeated as desired.
The truss assembly and splicing methods can be practiced simultaneously on the apparatus of the present invention. That is, on a single pass of the gantry press and splicing subassembly connector plates can be pressed into chord members in the splicing area and into a truss assemblies in the truss assembly zones A and C. Alternately, it will be readily apparent that the splicing subassembly can be operated independently of the truss assembly table and gantry press
14
. A separate splicing apparatus would not include the truss assembly area of the preferred embodiment. It is preferred that the truss assembly method and splicing method be practiced as explained, however, since this allows for splicing and truss assembly to occur on the same machine, thereby saving the time, space and labor involved in utilizing a splicing machine and then transferring the spliced chords to a separate truss assembly table.
Claims
- 1. A splicing apparatus for connecting chord members end-to-end, the apparatus comprising:a table having a table surface for supporting abutting chord members in end-to-end abutment; a gantry press mounted adjacent to the table surface and configured to move on gantry tracks relative to the table surface, the gantry press having at least two press rollers, each press roller having a peripheral surface positioned a successively closer clearance distance to the table surface.
- 2. A splicing apparatus as in claim 1, further comprising at least two end to end abutting chord members supported on the table surface, the chord members forming end-joints at each abutment; andfurther comprising at least one connector plate positioned above each end-joint whereby each of the press rollers presses the connector plates at least partially into the chord members as the gantry press moves relative to the table surface.
- 3. A splicing apparatus as in claim 2 further comprising at least one connector plate positioned below each end-joint.
- 4. A splicing apparatus as in claim 1 wherein the gantry press comprises five press rollers.
- 5. A splicing apparatus as in claim 4 wherein the peripheral surfaces of the at least two press rollers are positioned successively closer to the table surface in increments of no more than ⅛th of an inch.
- 6. A splicing apparatus as in claim 1 wherein the press rollers are adjustable whereby the clearance distances of the peripheral surfaces of the press rollers above the table surface can be adjusted.
- 7. A splicing apparatus as in claim 1 wherein the at least two press rollers are of similar size.
- 8. A splicing apparatus as in claim 1 wherein the table further comprises a surface for supporting truss assembly members.
- 9. A splicing apparatus as in claim 8 wherein the gantry press further comprises a splicing subassembly, at least one of the press rollers being supported above the table surface by the splicing subassembly.
- 10. A splicing apparatus as in claim 1 wherein the chord members are wooden.
- 11. A splicing apparatus for connecting chord members, the apparatus comprising:a table having a table surface for supporting at least two chord members in end-to-end abutment, the chord members forming end-joints at each end-to-end abutment; at least one connector plate positioned above each end-joint; a gantry press mounted to move relative to the table on gantry wheels; a plurality of press rollers mounted on the gantry press and above the table surface and configured to move relative to the table surface, each press roller having a peripheral surface, each press roller peripheral surface positioned a clearance distance above the table surface, the peripheral surfaces having successively smaller clearance distances such that the press wheels successively press each connector plate further into the chord members as the plurality of press rollers moves relative to the table surface.
- 12. A splicing apparatus as in 11 further comprising at least one connector plate positioned below each end-joint.
- 13. A splicing apparatus as in 11 wherein the plurality of press rollers comprises five press rollers.
- 14. A splicing apparatus as in 11 wherein the peripheral surfaces of the at least two press rollers are positioned successively closer to the table surface in increments of no greater than ⅛th of an inch.
- 15. A splicing apparatus as in 11 wherein the clearance distances of the peripheral surfaces of the plurality of press rollers are adjustable.
- 16. A splicing apparatus as in 11 wherein at least two of the plurality of press rollers are of similar size.
- 17. A splicing apparatus as in 11 wherein the table further comprises a surface for assembling members of a truss.
- 18. A splicing apparatus for connecting chord members end-to-end, the apparatus comprising:a table having a table surface for supporting abutting chord members; a gantry press, having gantry wheels, capable of moving relative to the table; a first and last press roller supported by the gantry press above the table surface and configured for movement relative to the table surface, the first press roller having a first roller peripheral surface positioned a first clearance distance above the table surface and the last roller having a last roller peripheral surface positioned a last clearance distance above the table surface, the first clearance distance greater than the last clearance distance.
- 19. A splicing apparatus as in 18, further comprising at least two abutting chord members supported on the table surface, the chord members forming end-joints at each abutment; andfurther comprising at least one connector plate positioned above each end-joint whereby the first and last press rollers each press the at least one connector plate at least partially into the chord members as the first and last press roller move relative to the table surface.
- 20. A splicing apparatus as in 19 further comprising at least one connector plate positioned below each end-joint.
- 21. A splicing apparatus as in 18 additionally comprising a second press roller supported above the table surface between the first and last press roller, the second press roller configured for movement relative to the table surface, the second press roller having a second peripheral surface positioned a second clearance distance above the table surface, the second clearance distance greater than the last clearance distance and less than the first clearance distance.
- 22. A splicing apparatus as in 21 wherein the difference between the peripheral distances of any two adjacent rollers is no greater than ⅛th of an inch.
- 23. A splicing apparatus as in 18 wherein the clearance distances of the peripheral surfaces of the press rollers can be adjusted.
- 24. A splicing apparatus as in 22 wherein the clearance distances of the peripheral surfaces of the first and second press rollers are adjustable.
- 25. A splicing apparatus as in 21 wherein the first and second press rollers are of the same size.
- 26. A method of splicing chord members end-to-end comprising the steps of:placing multiple wooden chord members in end-to-end abutment on a table surface, providing a gantry press movable along gantry tracks, the cord members having end-joints at each end-to-end abutment; placing at least one connector plate over each end-joint; pressing the at least one connector plate into the chord members with the gantry press supported above the table surface and configured for movement relative to the table surface, the gantry press having a plurality of press rollers, each press roller having a peripheral surface positioned successively closer to the table surface, each press roller incrementally pressing the at least one connector plate into the chord members.
- 27. A method as in claim 26, further comprising the step of placing at least one connector plate under each end-joint between chord members.
- 28. A method as in claim 26, the plurality of press rollers each having a peripheral surface, each peripheral surface having a clearance distance above the table surface; andfurther comprising the step of adjusting the clearance distances of the peripheral surfaces of the press rollers.
- 29. A method as in claim 26, the plurality of press rollers comprising five press rollers.
- 30. A method as in claim 29 wherein four of the press rollers are of the same size.
- 31. A method of splicing chord members comprising the steps of:placing two wooden chord members in end-to-end abutment on a table surface thereby forming an end-joint between the chord members; placing a connector plate over the end-joint; pressing the connector plate partially into the chord members with a first press roller; and pressing the connector plate partially into the chord members with a last press roller.
- 32. A method as in claim 31 further comprising the step of pressing the connector plate partially into the chord members with a second press wheel.
- 33. A method as in claim 31, the first and last press roller supported above the table surface a first and last clearance distance, respectively;further comprising the step of adjusting the first and last clearance distances.
- 34. A method as in claim 31 further comprising the step of placing a connector plate below the end-joint.
- 35. A truss assembly and chord splicing apparatus comprising:a table having a truss assembly surface for supporting a truss assembly; the table having a splicing surface for supporting end-to-end abutting chord members; a gantry press assembly mounted adjacent to the table and configured to move relative to the table on gantry tracks, the gantry press assembly having a primary press roller configured to move over the truss assembly surface, the gantry press assembly having at least two splicing press rollers configured to move over the splicing surface, the at least two splicing press rollers each having a peripheral surface positioned successively closer clearance distances above the splicing surface.
- 36. An apparatus as in claim 35 further comprising:a truss assembly having a plurality of abutting truss members positioned on the truss assembly surface, the truss members forming truss joints at each abutment; at least one connector plate positioned above each truss joint; at least two abutting chord members supported on the splicing surface, the chord members forming end-joints at each abutment; at least one connector plate positioned above each end-joint.
- 37. An apparatus as in claim 36 further comprising at least one connector plate positioned below each end-joint.
- 38. An apparatus as in claim 35 wherein the primary press roller is further configured to move over the splicing surface.
- 39. An apparatus as in claim 35 wherein each clearance distance is adjustable.
- 40. An apparatus as in claim 35 wherein the truss assembly surface and the splicing surface are different heights above a floor surface.
- 41. A truss assembly and chord splicing apparatus comprising:a truss assembly table having a truss assembly surface and a splicing surface; a gantry press having a primary press roller and a splicing subassembly, the subassembly comprising at least two splicing press rollers, the splicing press rollers each having a peripheral surface positioned a successively closer clearance distance above the splicing surface, the gantry press having gantry wheels designed to move along gantry tracks mounted adjacent the table.
- 42. An apparatus as in claim 41 further comprising:a plurality of truss assembly members in abutment supported on the truss assembly surface; a plurality of chord members supported in end-to-end abutment on the splicing surface; the truss assembly members and chord members forming joints at each abutment; and at least one connector plate positioned above each joint.
- 43. A method of forming a truss assembly and splicing a plurality of chord members, the method comprising the steps of:placing a plurality of truss assembly members in abutment on a truss assembly surface; placing a plurality of chord members in end-to-end abutment on a splicing surface, the truss assembly members and the chord members forming joints at each abutment; placing at least one connector plate above each abutment; and pressing the connector plates into the members by moving a gantry press over the truss assembly and splicing surfaces.
- 44. A method as in claim 43 wherein the gantry press comprises a primary press roller configured to move over the truss assembly surface and a plurality of splicing press rollers configured to move over the splicing surfaces.
- 45. A method as in claim 44 wherein the primary press roller is configured to move over the splicing surface.
- 46. A method as in claim 44 wherein the plurality of splicing press rollers each have a peripheral surface positioned a successively closer clearance distance above the splicing surface.
- 47. An assembly apparatus comprising:a table having a table surface with a splicing surface for supporting splice chord members in end-to-end abutment; the table surface having a truss assembly surface for supporting truss members; a gantry press positioned to move relative to the table surface, the gantry press operable to move on gantry tracks; a main roller, supported above the table by the gantry press, the main roller configured for pressing connector plates into truss members; a splicing sub-assembly having at least one splice roller, the splicing sub-assembly supported above the splicing surface by the gantry press, the at least one splice roller configured for pressing a connector plate into splice chord members.
- 48. An apparatus as in claim 47 wherein the at least one splice roller extends only across the splicing surface.
- 49. An apparatus as in claim 47 wherein the main roller extends across both the truss assembly surface and the splicing surface.
- 50. An apparatus as in claim 49, the main roller configured for at least partially pressing a connector plate into splice chord members.
- 51. An apparatus as in claim 50, the main roller having a peripheral surface positioned a main roller distance above the splicing surface, the at least one splice roller having a peripheral surface positioned a splice roller distance above the splicing surface, the splice roller and main roller operable to press a connector plate successively farther into splice chord members.
- 52. An apparatus as in claim 47, the splicing sub-assembly having multiple splice rollers, each of the splice rollers having a peripheral surface positioned at successively closer splice roller distances above the splicing surface such that each splice roller is capable of pressing a connector plate successively farther into splice chord members as the gantry press moves relative to the table surface.
- 53. An apparatus as in claim 50, the splicing sub-assembly having multiple splice rollers, each of the splice rollers having a peripheral surface positioned at successively closer splice roller distances above the splicing surface such that each splice roller is capable of pressing a connector plate successively farther into splice chord members as the gantry press moves relative to the table surface.
- 54. An apparatus as in claim 52 wherein each of the splice rollers is designed to press a connector plate into the splice chord members no more than ⅛th of an inch per roller.
- 55. An apparatus as in claim 52 wherein each of the splice rollers is designed to press a connector plate into the splice chord members no more than {fraction (1/16)}th of an inch per roller.
- 56. An apparatus as in claim 47 the splicing sub-assembly having four splice rollers.
- 57. An apparatus as in claim 47, the table having a second splicing sub-assembly mounted to the gantry press opposite the first splicing sub-assembly.
- 58. An apparatus as in claim 47 further comprising at least two end-to-end abutting splice chord members supported on the splicing surface, the splice chord members forming end-joints at each abutment; and further comprising at least one connector plate positioned above each end-joint whereby each of the rollers presses the connector plates at least partially into the chord members as the gantry press moves relative to the table surface.
- 59. An apparatus as in claim 58 further comprising at least one connector plate positioned below each end-joint.
- 60. An apparatus as in claim 47 wherein the at least one splice roller is adjustable.
- 61. An apparatus as in claim 52 wherein the splice roller distances above the splicing surface are at different heights above a floor surface.
- 62. An apparatus as in claim 47 wherein the truss assembly surface and the splicing surface are at different heights above a floor surface.
US Referenced Citations (16)