WO2007134459A1 - Poutrelles formant une machine de construction et procédé associé - Google Patents

Poutrelles formant une machine de construction et procédé associé Download PDF

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Publication number
WO2007134459A1
WO2007134459A1 PCT/CA2007/000924 CA2007000924W WO2007134459A1 WO 2007134459 A1 WO2007134459 A1 WO 2007134459A1 CA 2007000924 W CA2007000924 W CA 2007000924W WO 2007134459 A1 WO2007134459 A1 WO 2007134459A1
Authority
WO
WIPO (PCT)
Prior art keywords
structural member
joist
paneling
member assembly
assembly machine
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CA2007/000924
Other languages
English (en)
Inventor
Ben Bertrand
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Innovequity Inc
Original Assignee
Innovequity Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from PCT/CA2006/000844 external-priority patent/WO2006125309A1/fr
Application filed by Innovequity Inc filed Critical Innovequity Inc
Priority to CA2698122A priority Critical patent/CA2698122A1/fr
Publication of WO2007134459A1 publication Critical patent/WO2007134459A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/08—Seam welding not restricted to one of the preceding subgroups
    • B23K11/082—Seam welding not restricted to one of the preceding subgroups of three-dimensional seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/10—Spot welding; Stitch welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/30—Features relating to electrodes
    • B23K11/31—Electrode holders and actuating devices therefor
    • B23K11/312—Electrode holders and actuating devices therefor for several electrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/04—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
    • B23K37/0426—Fixtures for other work
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/35—Extraordinary methods of construction, e.g. lift-slab, jack-block
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C3/06—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web
    • E04C3/07—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web at least partly of bent or otherwise deformed strip- or sheet-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
    • E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
    • E04C2003/0426—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section
    • E04C2003/043—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section the hollow cross-section comprising at least one enclosed cavity

Definitions

  • the present invention relates to automated construction.
  • the invention relates to an apparatus and method for automatic construction of a building using a joist forming device.
  • a structural member assembly machine with a support frame having opposed entry and exit sides, opposed first and second ends; a structural member assembly area within the support frame; joist feeder means for feeding a plurality of joists end-on into the structural member assembly area, comprising a plurality of joist feeders releasably connected at spaced intervals on the entry side of the support frame; upper paneling feeder means connected to the support frame above the joist feeders for feeding upper paneling into the structural member assembly area; lower paneling feeder means connected to the support frame below the joist feeders for feeding lower paneling into the structural member assembly area; structural member assembly means in the structural member assembly area for assembling a plurality of joists, upper paneling and lower paneling into a structural member; structural member receiving means adjacent the exit side of the support frame for receiving a structural member, and drive means for moving the structural member from the assembly area to the structural member receiving means.
  • the joist feeder may have a housing; at least two rollers, each rotationally connected to the housing; a roll of a joist material wrapped on each roller; a template connected to the housing in spaced relationship to each roll of joist material, wherein the template includes an opening defining a joist circumference, joist material from each roll guidable through the opening so as to position at least one portion of each joist material adjacent to at least one portion of at least one other piece of joist material at a welding position; a welding head disposed in proximity to each welding position; means for connecting each welding head to a welding machine; and sensor means for selectively activating the welding machine to weld adjacent portions of joist material at each welding position to form a joist.
  • the at least two rollers may be four rollers and the joist circumference may be in the shape of an I-beam or a quadrilateral.
  • the at least two rollers may be three rollers and the joist circumference may be in the shape of a triangle having concave sides.
  • the joist feeder may have a housing having a roller attached; a roll of a joist material wrapped on the roller; a joist forming unit connected to the housing adjacent to the roll of joist material, wherein the joist forming unit comprises a series of wheels and presses for forming the joist material; at least one welding head disposed at a welding position adjacent the formed joist material; means for connecting each welding head to a welding machine; and sensor means for selectively activating the welding machine to weld the formed joist material at each welding position into a joist.
  • the structural member assembly machine may have joist fill means for inserting joist fill through the opening of the template into the interior space of each joist.
  • the joist fill means may be at least one tube for passage of joist fill from a fill source into each joist.
  • the joist fill may be a foam and. a bonding agent, concrete, or other structural fill material having an additive or characteristic permitting bonding of the material to the interior of the joist.
  • Each joist feeder may include corrugation means for corrugating a planar joist material to form a corrugated joist.
  • the corrugation means may be one or more gears rotationally connected to the support frame between the joist feeder and the structural member assembly area, through which the planar joist passes to form a corrugated joist, and corrugated joist bracing means between the joist feeder and the structural member assembly area.
  • the upper paneling feeder means may include a housing; a roller rotationally connected to the housing; a roll of upper paneling material wrapped on the roller; and guide means for positioning the upper paneling in an installation position adjacent the upper edges of the plurality of joists.
  • the upper paneling may be corrugated upper paneling.
  • the upper paneling means may further comprise corrugation means for corrugating upper paneling material to form corrugated upper paneling, the corrugation means positioned between the upper paneling feeder and the guide means.
  • the corrugation means may comprise a pair of gears rotationally connected to the support frame between the roll of upper paneling material and the structural member assembly area, through which the upper paneling material passes to form corrugated upper paneling.
  • the corrugation means may comprise at least one hydraulic press, each hydraulic press extending adjacent the frame between the upper paneling feeder and the structural member assembly area, for stamping a plurality of corrugation grooves into the upper paneling material to form corrugated upper paneling.
  • the upper paneling feeder means may comprise an upper paneling bay; a plurality of individual upper panels stacked in the upper paneling bay; and guide means for positioning the upper paneling in an installation position adjacent the upper edges of the plurality of joists.
  • the structural member assembly machine may further comprise an actuator connected to the support frame adjacent the rear side of the upper paneling feeder for horizontal dislocation of the lowermost upper panel from the upper paneling bay to an installation position adjacent the upper edges of the plurality of joists.
  • Each upper panel may have substantially planar upper and lower surfaces, irregular corrugations to control meshing of vertically adjacent upper panels, or synchronous corrugations with separators between upper panels to permit horizontal dislocation of a lowermost upper panel of vertically stacked upper panels.
  • Each joist may have irregular corrugation along the length of its upper edge corresponding to the irregular corrugation of the upper panels in a manner which prevents meshing of each upper panel with the upper edge of the joist until the joist is in the appropriate position for receiving the lowermost upper panel.
  • each joist may have synchronous corrugation along the length of its upper edge corresponding to the synchronous corrugation of each upper panel in a manner which permits movement of each joist to cause co-linear movement of an upper panel intermittently lowered into an installation position adjacent the joist.
  • the lower paneling means may comprise a housing; a roller rotationally connected to the housing; a roll of lower paneling material wrapped on the roller; guide means for positioning the lower paneling in an installation position adjacent the lower edges of the plurality of joists.
  • the lower paneling may be corrugated lower paneling.
  • the lower paneling means may further comprise corrugation means for corrugating lower paneling material to form corrugated lower paneling, the corrugation means positioned between the lower paneling feeder and the guide means.
  • the corrugation means may comprise a pair of gears rotationally connected to the support frame between the roll of lower paneling material and the structural member assembly area, through which the lower paneling material passes to form corrugated lower paneling.
  • the corrugation means may comprise at least one hydraulic press, each hydraulic press extending adjacent the frame between the lower paneling feeder and the structural member assembly area, for stamping a plurality of corrugation grooves into the lower paneling material to form corrugated lower paneling.
  • the lower paneling feeder means may comprise a lower paneling bay; a plurality of individual lower panels stacked in the lower paneling bay; and guide means for positioning the lower paneling in an installation position adjacent the lower edges of the plurality of joists.
  • An actuator may be connected to the support frame adjacent the rear side of the lower paneling feeder for horizontal dislocation of the uppermost lower panel from the lower paneling bay to an installation position adjacent the lower edges of the plurality of joists.
  • Each lower panel may have substantially planar upper and lower surfaces, irregular corrugations to prevent meshing of vertically adjacent lower panels, or synchronous corrugations with separators: between adjacent lower panels to permit horizontal dislocation of an uppermost lower panel of vertically stacked lower panels.
  • Each joist may have irregular corrugation along the length of its lower edge corresponding to the irregular corrugation of the lower panels in a manner which prevents meshing of each lower panel with the lower edge of the joist until the joist is in the appropriate position for receiving the uppermost lower panel.
  • each joist may have synchronous corrugation along the length of its lower edge corresponding to the synchronous corrugation of each lower panel in a manner which permits movement of each joist to cause co-linear movement of an lower panel intermittently raised into an installation position adjacent the joist.
  • the structural member assembly means may further comprise fastening means for fastening the upper paneling to the joist material and the joist material to the lower paneling.
  • the fastening means may include mechanical fasteners such as screws, rivets, nails and staples and associated automated fastening devices such as screw guns or nail guns.
  • the fastening means may include at least one welding device, which may be adapted to weld together the joist and the upper paneling, as well as the joist and the lower paneling.
  • the structural member receiving means may be a constructed platform, a horizontal construction surface of a building under construction, or a vehicle bed.
  • the strudural member assembly machine may include utility line insertion means for inserting utility lines during assembly of the assembled structural member.
  • the structural member assembly machine may include insulation insertion means for inserting insulation material during assembly of the assembled structural member.
  • the insulation insertion means may include at least one insulation feeder tube having a dispensing end positioned adjacent the structural member assembly area for dispensing the insulation material into the interior of the structural member.
  • the insulation material may be sprayable polyurethane foam insulation, loose-fill fibre insulation, or other sprayable or blow-in form of insulation.
  • the structural member assembly machine may include finishing material application means for applying a finishing material to the assembled structural member. It may also include vapour barrier application means for applying a vapour barrier to the assembled structural member.
  • the structural member assembly machine may include a plurality of parallel trusses extending perpendicularly to the joists between opposed ends of the frame and releasably fastened to each joist to provide structural support during assembly of the structural member.
  • Each parallel truss may be fastened to the upper edges of the joists or to the lower edges of the joists.
  • the plurality of parallel trusses may extend beyond the ends of the frame and further comprises rollable support means fixed to the ends of each truss for supporting the truss and the structural member.
  • a method of constructing an assembled structural member comprising the steps of extruding initial portions of a plurality of parallel joists from a plurality of joist feeders into a structural member assembly area to form a joist array having opposing upper and lower faces; positioning upper paneling adjacent the upper face of the joist array and lower paneling adjacent the lower face of the joist array; fastening each of the upper paneling and lower paneling to the joists of the joist array; extruding subsequent portions of the plurality of parallel joists into the structural member assembly area; repeating the steps of positioning upper paneling adjacent the upper face of the joist array and lower paneling adjacent the lower face of the joist array; fastening each of the upper paneling and lower paneling to the joists of the joist array; and extruding subsequent portions of the plurality of parallel joists into the structural member assembly area until a desired joist length has been achieved; and repeating
  • the method of constructing an assembled structural member may include any of the additional steps of inserting utility lines during assembly of the assembled structural member, inserting insulation during assembly of the assembled structural member, applying a finishing material to the assembled structural member, or applying a vapour barrier to the assembled structural member.
  • a welding apparatus for manufacturing a longitudinal structural element, comprising a housing; at least two rollers, each rotationally connected to the housing; a roll of structural material wrapped about each roller; means for feeding the end of each roll of structural material through a template connected to the housing in spaced relationship to each roll of structural material, wherein the template includes an opening defining a structural circumference, structural material from each roll guidable through the opening so as to position at least one portion of each piece of structural material adjacent to at least one portion of at least one other piece of structural material at a welding position; a welding head disposed in proximity to each welding position; means for connecting each welding head to a welding machine; and sensor means for selectively activating the welding machine to weld adjacent portions of structural material at each welding position to form a longitudinal structural element.
  • the at least two rollers may be four rollers and the structural circumference may be in the shape of an I-beam or a quadrilateral.
  • the at least two rollers may be three rollers and the structural circumference may be in the shape of a triangle having concave sides.
  • the longitudinal structural elements may be joists, ducting, concrete forms or other similar structural members.
  • the welding apparatus may also include structural fill means for inserting structural fill through the opening of the template into the interior space of each longitudinal structural element.
  • a method of manufacturing a longitudinal structural element comprising the steps of feeding at least two flexible siructural material feedstocks in spaced orientation through a first side of a template, wherein the template guides at least one portion of each feedstock into a position adjacent to a corresponding portion of at least one other feedstock; welding each of the pairs of adjacent portions together in the vicinity of the template to form a longitudinal structural element; repeating these steps until the longitudinal structural element is of a desired length; and separating the longitudinal structural element from the at least two structural material feedstocks.
  • the at least two feedstocks may be four feedstocks and the template circumference may be in the shape of an I-beam or a quadrilateral.
  • the at least two feedstocks may be three feedstocks and the template circumference may be in the shape of a triangle having concave sides.
  • the longitudinal structural elements may be joists, ducting, concrete forms or similar.
  • FIG. 1 is a perspective view of a structural member assembly machine, according to one embodiment of the invention.
  • FIG. 2 is a perspective view of a joist feeder, according to one embodiment of the invention.
  • FIG. 3 is a perspective top view of a joist feeder, according to one embodiment of the invention, showing opposed wheel drive means;
  • FIG. 4 is a perspective view of a joist feeder, according to one embodiment of the invention.
  • FIG. 5 is a perspective view of a structural member assembly machine, according to one embodiment of the invention.
  • FIG. 6 is a perspective view of a joist feeder, according to one embodiment of the invention.
  • FIG. 7 is a frontal view of a joist feeder showing a template, according to one embodiment of the invention.
  • FIG. 8 is a perspective view of a joist feeder showing a template, according to one embodiment of the invention.
  • FIG. 9 is a perspective view of a joist feeder showing a joist section bay, according to one embodiment of the invention.
  • FIG. 10 is a perspective view of a joist feeder showing a joist section bay, according to one embodiment of the invention.
  • FIG. 11 is a perspective view of a joist feeder showing a joist section bay, according to one embodiment of the invention
  • FIG. 12 is a perspective view of a joist feeder showing a joist section bay, according to one embodiment of the invention
  • FIG. 13 i is a perspective view of a joist feeder showing a press device, according to one embodiment of the invention.
  • FIG. 14 is a perspective view of a joist feeder showing bevelled ended joist sections, according to one embodiment of the invention.
  • FIG. 15 is a perspective view of a joist feeder showing bevelled ended joist sections, according to one embodiment of the invention.
  • FIG. 16 is a perspective view of a plurality of joist feeders, according to one embodiment of the invention.
  • FIG. 17 is a perspective view of a joist exiting a joist feeder, according to one embodiment of the invention.
  • FIG. 18 is a perspective view of a joist feeder showing corrugation gears, according to one embodiment of the invention.
  • FIG. 19 is a perspective view of a joist feeder using a prior art corrugation means
  • FIG. 20 is a perspective view of a structural member assembly machine using a prior art corrugation means, according to one embodiment of the invention.
  • FIG. 21 is a perspective view of a joist feeder, showing joist bracing means, according to one embodiment of the invention.
  • FIG. 22 is a side view of a structural member assembly machine, according to one embodiment of the invention.
  • FIG. 23 is a perspective view of a structural member assembly machine using a prior art joist corrugation means, according to one embodiment of the invention.
  • FIG. 24 is a perspective view of a structural member assembly machine using a prior art joist corrugation means, according to one embodiment of the invention
  • FIG. 25 is a perspective view of a structural member assembly machine using a prior art joist corrugation means, according to one embodiment of the invention
  • FIG. 26 is a perspective view of a structural member assembly machine showing upper and lower paneling bays, according to one embodiment of the invention.
  • FIG. 27 is a side view of a structural member assembly machine, showing non-engagement of the upper and lower panels with the irregularly corrugated joist, according to one embodiment of the invention.
  • FIG. 28 is a side view of a structural member assembly machine, showing engagement of the upper and lower panels with the irregularly corrugated joist, according to one embodiment of the invention.
  • FIG. 29 is a perspective view of a structural member assembly machine, showing a planar joist array, according to one embodiment of the invention.
  • FIG. 30 is a side view of a structural member assembly machine, showing an upper panel actuator in a raised position, according to one embodiment of the invention.
  • FIG. 31 is a side view of a structural member assembly machine, showing an upper panel actuator in a lowered position, according to one embodiment of the invention.
  • FIG. 32 is a perspective view of a corrugated upper panel, showing a slot cut to receive a joist, according to one embodiment of the invention.
  • FIG. 33 is a side view of a structural member assembly machine, showing fastener means external to the structural member, according to one embodiment of the invention.
  • FIG. 34 is a side view of a structural member assembly machine, showing fastener means internal to the structural member, according to one embodiment of the invention.
  • FIG. 35 is a perspective view of a welding device, according to one embodiment of the invention.
  • FIG. 36 is a side view of a structural member assembly machine, showing welding of a joist to upper and lower panels to extract the panels from the panel bays, according to one embodiment of the invention;
  • FIG. 37 is a perspective view of a structural member receiving means, according to one embodiment of the invention.
  • FIG. 38 is a perspective view of a structural member assembly machine, showing a line insertion spool, according to one embodiment of the invention.
  • FIG. 39 is a perspective view of a structural member assembly machine adjacent a structural member receiving means, according to one embodiment of the invention.
  • FIG. 40 is a perspective view of a truss attached below a structural member, according to one embodiment of the invention.
  • FIG. 41 is a perspective view of a structural member assembly machine adjacent a structural member receiving means, showing a wheeled support attachment, according to one embodiment of the invention.
  • FIG. 42 is a side view of a truss attachment device, according to one embodiment of the invention.
  • a structural member assembly machine 2 As shown in Fig. 1 , according to one embodiment of the present invention, there is provided a structural member assembly machine 2.
  • the machine has a support frame 4 having opposed entry 6 and exit 8 sides, opposes first 10 and second 12 ends; and defines a structural member assembly area 14 within the frame.
  • Joist feeder means comprising a plurality of joist feeders 16, for feeding a plurality of joists on- edge into the structural member assembly area 14, is disposed along the length of the entry side of the frame.
  • "on-edge” means the spatial orientation in which the planar surface of a material is generally in a vertical position with one longitudinal edge below the planar surface and one longitudinal edge above the planar surface.
  • a row of joist feeders is connected at spaced intervals at a medial position on the entry side of the support frame.
  • Upper paneling feeder means 18 is connected to the support frame at a position above the joist feeders, for feeding upper paneling into the structural member assembly area.
  • lower paneling feeder means 20 is connected to the support frame below the joist feeders, for feeding lower paneling into the structural member assembly area.
  • Structural member assembly means may be disposed in the structural member assembly area, for assembling a plurality of joists, upper paneling and lower paneling into a structural member.
  • Structural member receiving means may be located adjacent the exit side of the support frame, for receiving a structural member.
  • Drive means for moving the structural member from the structural member assembly area to the structural member receiving means, may be located within or outside of the support frame.
  • heating means such as gas torches, may be connected to or in proximity to the support frame to heat rolls of joist or panelling material to increase ease of unrolling.
  • the drive means to provide horizontal movement of the structural member through the machine may be effected by feeding the joists 22 between a first surface 24 comprising one or more adjacent moving wheels, sprockets, chains or belts, and an opposing second surface 26 which may be either a stationary surface, such as a brace, or a second moving surface comprising one or more wheels, sprockets, chains or belts. These wheels, sprockets, chains or belts may be located between the joist feeder means and the structural member assembly area.
  • Fig. 5 depicts the horizontal movement of the structural member out of the exit side of the support frame.
  • Upper paneling 28 and lower paneling 30 are connected to joists 22 by fastening means, such as a welding device 32.
  • the upper and lower paneling of the structural member is threaded between a moving surface 34 of wheels, sprockets, chains or belts and an opposing surface 36 which is either a stationary surface (not shown) or a second moving surface of wheels, sprockets, chains or belts.
  • These wheels, sprockets, chains or belts may be located adjacent against the upper or lower paneling, or both, on the exit side 8 of the upper paneling feeder means 18 and lower paneling feeder means 20.
  • the upper or lower paneling materials may be fed into one or an opposed pair of gears for corrugating the paneling.
  • the joist feeder 16 may have a housing 38; at least two rollers 40, each rotationally connected to the housing; a roll of a joist material 42 wrapped on each roller; a template 44 connected to the housing in spaced relationship to each roll of joist material, wherein the template includes an opening defining a joist circumference, joist material from each roll guidable through the opening so as to position at least one portion of each joist material adjacent to at least one portion of at least one other piece of joist material at a welding position 48; at least one welding head 50 disposed in proximity to each welding position; connection means 52 for connecting each welding head to a welding machine (not shown); and sensor means 54 for selectively activating the welding machine to weld adjacent portions of joist material at each welding position to form a joist 22.
  • the at least two rollers may be four rollers and the joist circumference may be in the shape of an I-beam or a quadrilateral. Alternatively, the at least two rollers may be three rollers and the joist circumference may be in the shape of a triangle having concave sides. Other joist shapes are also contemplated as being within the scope of the present invention.
  • the joist feeder may comprise a joist section bay 56.
  • Joist sections 58 may be extruded individually from the joist section bay by one or more horizontal actuators 60 which separate one joist section from the joist sections remaining in the bay by pushing the joist section out of the bay, then retracting and repeating the process.
  • Sequentially separated joist sections may be attached at their ends to form a joist 22.
  • the first joist section may be stopped by a press device 62 in alignment with a vertically mobile welding head 64 for welding the joist sections together.
  • the press device may be used to align the trailing end of a first joist section with the leading end of the next joist section.
  • the actuators may connect to the joist by pushing on the front edge of a cut-out in the joist's webbing. They may comprise a sub-actuator that penetrates the joist section or two opposed actuators which each press against the joist section as they move forward. The pair of actuators may keep the joist sections in alignment with the press device.
  • the joist sections 58 may be oppositely bevelled at each end to permit staggered overlapping of joist sections.
  • the joist sections may be extruded alternately from opposing sides of the joist section bay 56 by one or more horizontal actuators 60 which separate one joist section from the joist sections remaining in the corresponding side of the bay by pushing the joist section out of the bay, then retracting and repeating the process.
  • Sequentially extracted joist sections may be laminated together to form a joist.
  • perpendicular joists may be cantilevered to reduce immediate sagging and rotation by applying a first smooth rotating surface 66 near the entry side of the support frame above and in contact with the joists, and a second smooth rotating surface (not shown) near the exit side of the support frame below and in contact with the joist.
  • joists may have glue applied to upper and lower edges by a porous roller or dispenser located outside the joist bay to be extruded into the joist bay into installation positions.
  • the joists may have pegs fastened to upper and lower edges prior to entering the joist bay. These pegs may be installed by punching the underside of a joist's flanges to create a metal extrusion which may act as a fastening peg.
  • the upper and lower paneling is penetrable by the pegs during assembly of the structural member.
  • the structural member assembly machine may have joist fill means for inserting joist fill through the opening of the template into the interior space of each joist.
  • the joist fill means may be at least one lube for passage of joist fill from a fill source into each joist.
  • the joist fill may be a foam and a bonding agent, concrete, or other structural fill material having an additive or characteristic permitting bonding of the material to the interior of the joist.
  • each joist feeder may include corrugation means for corrugating a planar joist material to form a corrugated joist material.
  • the corrugation means may be one or more gears rotationally connected to the support frame between the joist feeder and the structural member assembly area, through which the planar joist material passes to form a corrugated joist material, and joist material bracing means 70 between the joist feeder and the structural member assembly area.
  • the joist feeder may have a housing 38 having a roller attached; a roll of a joist material 42 wrapped on the roller; a joist forming unit 72 connected to the housing adjacent to the roll of joist material, wherein the joist forming unit comprises a series of wheels and presses for forming the joist material (not shown); at least one welding head 50 disposed at a welding position adjacent the formed joist material; means for connecting each welding head to a welding machine; and sensor means for selectively activating the welding machine to weld the formed joist material at each welding position into a joist.
  • This device can be used in the present invention, as shown in Fig. 20 in which the joist feeders are attached to the frame on the entry side and the force used to extrude the corrugated joists may be employed to provide the force to move the joists in the machine direction 74.
  • bracing may be provided to prevent rotation of the joist and to ensure proper alignment with welding or other fastening devices.
  • Bracing may be in the form of strips of material 76 which create a support channel for the joist which does not allow the joist to deviate from proper alignment.
  • the upper paneling feeder means may include a housing 78; a roller 80 rotationally connected to the housing; a roll of upper paneling material 82 wrapped on the roller; and guide means 84 for positioning the upper paneling in an installation position adjacent the upper edges of the plurality of joists 86.
  • the upper paneling may be corrugated upper paneling, as shown in Figs. 24 and 25.
  • the upper paneling means may further comprise corrugation means for corrugating planar upper paneling to form corrugated upper paneling, the corrugation means positioned between the upper paneling feeder and the guide means.
  • the corrugation means may comprise a pair of gears 88 rotationally connected to the support frame 4 between the roll of upper paneling and the structural member assembly area, through which the upper paneling material passes to form corrugated upper paneling.
  • the corrugation means may comprise at least one hydraulic press (not shown), each hydraulic press extending adjacent the frame between the upper paneling feeder and the structural member assembly area, for stamping a plurality of corrugation grooves into the upper paneling material to form corrugated upper paneling.
  • the upper paneling feeder means may comprise an upper paneling bay 90; a plurality of individual upper panels 92 stacked in the upper paneling bay; and guide means for positioning the upper paneling in an installation position adjacent the upper edges of the plurality of joists.
  • the structural member assembly machine may further comprise an actuator 94 connected to the support frame adjacent the entry side of the upper paneling feeder for horizontal dislocation of the lowermost upper panel from the upper paneling bay to an installation position adjacent the upper edges of the plurality of joists 86.
  • Individual upper panels may be stacked directly above the joists.
  • One or more actuators push the lowest upper panel out from under the upper paneling bay.
  • Upper panels are pushed into an installation position with the leading edge of the panel aligned with a welding head 50.
  • the upper panels will fall into place on top of the joist array.
  • the welding head connects the upper panel to the joists.
  • the structural member 96 is then extruded until the trailing edge of the joists and panels is in alignment with the welding heads.
  • Subsequent upper panels are positioned above the joists with the leading edge abutting the trailing edge of the preceding upper panel, then welded to the joist array. The process is repeated until the structural member is complete.
  • the upper paneling material may have a corrugated lower side with pattern which only allows the paneling to fall onto the joist when the corrugation of the upper edge of the joist corresponds to the paneling.
  • the paneling would have its largest indentation at its rear edge to prevent the rear edge from falling into the joist corrugation until the joist is in the appropriate installation position beneath the paneling.
  • Paneling with a corrugated lower edge may be lowered into position adjacent joists with male to female corresponding upper edges and paneling with a corrugated upper edge may be raised into a position adjacent the same joists having a corresponding lower edge.
  • the lower paneling may be raised by a lower panel actuator which would keep upward pressure on the paneling until the uppermost panel has been entirely removed from the lower paneling bay.
  • the upper panel may be lowered onto the joists by members attached to the upper paneling bay which support the panels from underneath.
  • actuators situated within the support members may extrude vertically to prevent the next panel from prematurely falling onto the joists'.
  • the vertical actuators descend allowing the next panel to fall onto the joist corrugation.
  • Glue applicators for fastening the panels to the joists may be located inside or outside of the paneling bay.
  • Each upper panel may have substantially planar upper and lower surfaces, irregular corrugations to prevent meshing of vertically adjacent upper panels, or synchronous corrugations with separators between upper panels to permit horizontal dislocation of a lowermost upper panel of vertically stacked upper paneling.
  • each joist 22 may have irregular corrugation along the length of its upper edge corresponding to the irregular corrugation of the upper panels 92 in a manner which prevents meshing of each upper panel with the upper edge of the joist until the joist is in the appropriate position for receiving the lowermost upper panel.
  • the joists may instead have planar edges, as shown in Fig. 29.
  • each joist may have synchronous corrugation along the length of its upper edge corresponding to the synchronous corrugation of each upper panel in a manner which permits movement of each joist to cause co-linear movement of an upper panel intermittently lowered into an installation position adjacent the joist, as shown in Figs. 30 and 31.
  • the lower paneling means may comprise a housing 100; a roller 20 rotationally connected to the housing; a roll of lower paneling 102 wrapped on the roller; guide means 104 for positioning the lower paneling in an installation position adjacent the lower edges of the plurality of joists.
  • the lower paneling may be corrugated lower paneling.
  • the lower paneling means may further comprise corrugation means for corrugating lower paneling material to form corrugated lower paneling, the corrugation means positioned between the lower paneling feeder and the guide means.
  • the corrugation means may comprise a pair of gears rotalionally connected to the support frame between the roll of lower paneling material and the structural member assembly area, through which the lower paneling material passes to form corrugated lower paneling.
  • the corrugation means may comprise at least one hydraulic press, each hydraulic press extending adjacent the frame between the lower paneling feeder and. the structural member assembly area, for stamping a plurality of corrugation grooves into the lower paneling material to form corrugated lower paneling.
  • the lower paneling feeder means may comprise a lower paneling bay 106; a plurality of individual lower panels stacked in the lower paneling bay; and guide means for positioning the lower paneling in an installation position adjacent the lower edges of the plurality of joists.
  • An actuator 1 10 may be connected to the support frame adjacent the rear side of the lower paneling feeder for horizontal dislocation of the uppermost lower panel from the lower paneling bay to an installation position adjacent the lower edges of the plurality of joists.
  • Individual lower panels may be stacked directly below an array of joists.
  • One or more actuators may push the uppermost lower panel out from the lower paneling bay.
  • Lower panels are pushed into an installation position with the leading edge of the panel aligned with a welding head.
  • the structural member is then extruded until the trialing edge of the joists and panels is in alignment with the welding heads.
  • the lower panel may be raised into position against the joist array by a vertical actuator (not shown).
  • the welding head connects the lower panel to the joists.
  • Upper and lower panels may be simultaneously positioned and welded. Subsequent lower panels are positioned below the joists with the leading edge abutting the trailing edge of the preceding lower panel, then welded to the joist array. The process is repeated until the structural member is complete.
  • Each lower panel may have substantially planar upper and lower surfaces, irregular corrugations to prevent meshing of vertically adjacent lower panels, or synchronous corrugations with separators between adjacent lower panels to permit horizontal dislocation of an uppermost lower panel of vertically stacked lower paneling.
  • upper or lower paneling may be comprised of solid panels stacked on longitudinal edge, each panel hingedly connected to the next adjacent panels along its longitudinal edges.
  • a first panel would be installed onto the joists and be extruded.
  • Each subsequent panel would immediately begin to rotate flat into an installation position on the joists.
  • Each joist may have irregular corrugation along the length of its lower edge corresponding to the irregular corrugation of the lower panels in a manner which prevents meshing of each lower panel with the lower edge of the joist until the joist is in the appropriate position for receiving the uppermost lower panel.
  • each joist may have synchronous corrugation along the length of its lower edge corresponding to the synchronous corrugation of each lower panel in a manner which permits movement of each joist to cause co-linear movement of an lower panel intermittently raised into an installation position adjacent the joist.
  • corrugated paneling may have one or more continuous slots 112 cut through its underside for receiving the edge of extruded joists. As the joist is connected to the paneling the paneling acts as a structural flange. The paneling may be cut to an extent that only the upper portion of the corrugation would remain.
  • the joist feeders may extrude a sufficiently long portion of joist to reach the fastening means, then paneling may be connected to the leading top and bottom edges of the joist.
  • the joist feeders may extrude a further portion of the joists, thereby moving the structural member onto a structural member receiving structure.
  • a glue dispenser may be used to apply glue to the upper and lower edges of a joist as it is being produced to permit attachment to upper and lower paneling.
  • the structural member assembly means may further comprise fastening means for fastening the upper paneling to the joist material and the joist material to the lower paneling.
  • the fastening means may include mechanical fasteners such as screws, rivets, nails and staples, along with devices such as staple and nail guns for applying these mechanical fasteners.
  • one or more fastener guns 114 may be positioned on the leading edge of the frame to connect the paneling to the joists.
  • Fastening guns may be positioned internal to or external to the structural member during assembly. Gluing may also be used to connect joists to paneling.
  • the fastening means may include at least one welding device, which may be adapted to weld together the joist and the upper paneling, as well as the joist and the lower paneling. Welding may be internal or external to the structural member. As shown in Fig. 35, welding devices 116 may be stationary and may use the horizontal movement of the structural member to make a continuous or intermittent welded connection.
  • the welding heads 50 may continuously connect corrugated material by incorporating wheels 118 and a spring 120 or dampener which allows the welding head to move with the varying heights of the corrugation. This movement may occur along two axes by including stationary smooth braces outside of the spring.
  • Plates made from a high heat resistance material may be positioned on the opposite side of the paneling from the welding heads to exert pressure firmly onto the joist during welding. These plates may be liquid cooled.
  • paneling may be extruded by welding a small strip of paneling to the top and bottom edge of ajoist, as shown in Fig. 36. The joist will extrude the paneling as it moves.
  • the structural member receiving means may be a constructed platform 122, as shown in Fig. 37.
  • the structural member receiving means may be a horizontal construction surface of a building under construction or a vehicle bed.
  • the structural member assembly machine may include utility line insertion means for inserting utility lines during assembly of the assembled structural member.
  • the lines and wires may include plumbing, HVAC ducts, electrical wires or any other duct, tube or wire- like material that is normally placed within walls or floors of a conventional building.
  • the wires and pipes 124 are coiled on spools 126 or in boxes at the entry side of the support frame and each is feedable between the paneling materials and connectable to the leading edge of the structural member. As the structural member moves in the machine direction, lines are installed in the assembly process, wires and pipes will be pulled along and threaded through the structural member.
  • the line materials may be placed on the leading edge of the structural member, threaded through the joist bay and connected to the an anchor point on or near the support frame.
  • the line materials may be moved along with the structural member assembly as it is moved forward.
  • the line materials may be located on the exit side of the machine, threaded through the joist bay and connected to an anchor point on or near the machine.
  • the structural member assembly machine may include insulation insertion means for inserting insulation material during assembly of the assembled structural member.
  • the insulation insertion means may include at least one insulation feeder tube having a dispensing end positioned adjacent the structural member assembly area for dispensing the insulation material into the interior of the structural member.
  • the insulation material may be sprayable polyurethane foam insulation, loose-fill fibre insulation, or other sprayable or blow-in forms of insulation.
  • the structural member assembly machine may include finishing material application means for applying a finishing material to the assembled structural member. It may also include vapour barrier application means for applying a vapour barrier to the assembled structural member.
  • finishing material application means for applying a finishing material to the assembled structural member.
  • vapour barrier application means for applying a vapour barrier to the assembled structural member.
  • the application of carpet, linoleum or other material may have a corrugated underside which runs perpendicular to the paneling corrugation.
  • Semi rigid or fully rigid floor or wall finishing panels may be placed on the corrugation. Concrete, plaster or similar material dispensers may be used to fill the corrugation. Trowels may be used to smooth the upper surface.
  • the structural member assembly machine may include a plurality of parallel trusses 128 extending perpendicularly to the joists between opposed ends (12, 14) of the frame and releasably fastened to each joist to provide structural support during assembly of the structural member.
  • the truss will transfer the load of the structural member to a structural member receiving means 136.
  • each parallel truss may be fastened to the upper edges of the joists or to the lower edges of the joists, may extend beyond the lateral edges of the structural member and may have wheeled support attachments 132 which may roll on the structural member receiving means to reduce friction.
  • the support trusses may be installed above or below the joists of the structural member. The attachment of these support trusses may be automated.
  • a computer-controlled arm 138 may align a truss with fasteners which temporarily fasten the truss to the joists through the paneling.
  • the structural member assembly can be supported by an extrusion 134 near the edge of a truss.
  • the support truss does not require vertical extensions, but must contact the edge of the structural member receiving means suspending the structural member assembly. The weight of the structural member is transferred to the structural member receiving means.
  • Each support truss is connectable to the joists of the structural member at positions corresponding to the maximum span of the extruded joists. After production, the support trusses may be disconnected to allow the structural member to rest on its permanent support structure.
  • a second roll of non-corrugated paneling may be connected to the outer surface of the corrugated paneling by applying glue to the upper ridges of the surface then pressing on the non-corrugated paneling, or by mechanically fastening the flat surface to the corrugation by pressing both surfaces together then puncturing both surfaces to maintain a flush external finish.
  • the opening through which the paneling is extruded is selected to be the same height as the corrugated material plus the flat paneling.
  • a method of constructing a structural member comprising the steps of extruding initial portions of a plurality of parallel joists from a plurality of joist feeders into a structural member assembly area to form a joist array having opposing upper and lower faces; positioning upper paneling adjacent the upper face of the joist array and lower paneling adjacent the lower face of the joist array; fastening each of the upper paneling and lower paneling to the joists of the joist array; extruding subsequent portions of the plurality of parallel joists into the structural member assembly area; repeating the steps of positioning upper paneling adjacent the upper face of the joist array and lower paneling adjacent the lower face of the joist array; fastening each of the upper paneling and lower paneling to the joists of the joist array; and extruding subsequent portions of the plurality of parallel joists into the structural member assembly area until a desired joist length has been achieved; and repeat
  • the method of constructing a structural member may include any of the additional steps of inserting utility lines during assembly of the structural member, inserting insulation during assembly of the structural member, applying a finishing material to the structural member, or applying a vapour barrier to the structural member.
  • an apparatus for manufacturing a longitudinal structural element comprising a housing; at least two rollers, each rotationally connected to the housing; a roll of structural material wrapped about each roller; means for feeding the end of each roll of structural material through a template connected to the housing in spaced relationship to each roll of structural material, wherein the template includes an opening defining a structural circumference, structural material from each roll guidable through the opening so as to position at least one portion of each piece of structural material adjacent to at least one portion of at least one other piece of structural material at a welding position; a welding head disposed in proximity to each welding position; means for connecting each welding head to a welding machine; and sensor means for selectively activating the welding machine to weld adjacent portions of structural material at each welding position to form a longitudinal structural element.
  • the at least two rollers may be four rollers and the structural circumference may be in the shape of an I-beam or a quadrilateral.
  • the at least two rollers may be three rollers and the structural circumference may be in the shape of a triangle having concave sides.
  • the longitudinal structural elements may be joists, ducting, concrete forms or other similar structural members.
  • the welding apparatus may also include structural fill means for inserting structural fill through the opening of the template into the interior space of each longitudinal structural element.
  • a joist or similar longitudinal structural element using rolled joist material.
  • Rolls of joist material may be fed through a template that brings the edges or faces of the rolled material together, allowing them to be connected to form a structural joist.
  • rolls of pre-corrugated material may be unrolled to form a joist.
  • a roll of joist material may unrolled and fed into opposed gears that press corrugation into it. These gears can also act as drive means to move the joist in the machine direction.
  • a method of manufacturing a longitudinal structural element comprising the steps of feeding at least two flexible structural material feedstocks in spaced orientation through a first side of a template, wherein the template guides at least one portion of each feedstock into a position adjacent to a corresponding portion of at least one other feedstock; welding each of the pairs of adjacent portions together in the vicinity of the template to form a longitudinal structural element; repeating these steps until the longitudinal structural element is of a desired length; and separating the longitudinal structural element from the at least two structural material feedstocks.
  • the at least two feedstocks may be four feedstocks and the template circumference may be in the shape of an I-beam or a quadrilateral.
  • the at least two feedstocks may be three feedstocks and the template circumference may be in the shape of a triangle having concave sides.
  • the longitudinal structural elements may be joists, ducting, concrete forms or similar.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Electromagnetism (AREA)
  • Optics & Photonics (AREA)
  • Floor Finish (AREA)

Abstract

L'invention concerne une machine et le procédé associé de construction automatisée de bâtiments. Une machine d'assemblage d'éléments structurels comprend une structure de support, une surface de montage des éléments structurels dans la structure de support, un dispositif d'alimentation en poutrelles pour fournir une pluralité de poutrelles sur le bord de la surface de montage des éléments structurels, un moyen d'alimentation en panneaux supérieur relié à la structure de support au-dessus du système d'alimentation en poutrelles, un moyen d'alimentation en panneaux inférieur relié à cette même structure sous le système d'alimentation en poutrelles, un moyen d'alimentation en panneaux de la structure de support permettant d'assembler une pluralité de poutrelles, des panneaux supérieurs et inférieurs insérés dans un élément structurel, des moyens de réception de membre structurels pour recevoir un membre structurel et des moyens d'entraînement pour déplacer le membre structurel le long de la machine.
PCT/CA2007/000924 2006-05-23 2007-05-23 Poutrelles formant une machine de construction et procédé associé Ceased WO2007134459A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2698122A CA2698122A1 (fr) 2006-05-23 2007-05-23 Poutrelles formant une machine de construction et procede associe

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
PCT/CA2006/000844 WO2006125309A1 (fr) 2005-05-23 2006-05-23 Systeme de construction automatique
CAPCT/CA06/00844 2006-05-23
US81368306P 2006-06-15 2006-06-15
US60/813,683 2006-06-15

Publications (1)

Publication Number Publication Date
WO2007134459A1 true WO2007134459A1 (fr) 2007-11-29

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116950421A (zh) * 2023-09-06 2023-10-27 刘诗琪 一种装配式建筑施工工艺

Citations (8)

* Cited by examiner, † Cited by third party
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US3962773A (en) * 1972-09-19 1976-06-15 Lely Cornelis V D Methods for the manufacture of prefabricated building sections or room units and factories for the implementation of such methods
US4485608A (en) * 1982-07-13 1984-12-04 Restroom Facilities Corporation Prefabricated, self-contained building and method of construction
US5074457A (en) * 1988-08-11 1991-12-24 Fuji Photo Film Co., Ltd. Method and apparatus for splicing metal webs
US5123587A (en) * 1991-06-11 1992-06-23 Owen Joist Corporation Method and apparatus for making steel joists
US6288355B1 (en) * 1996-04-22 2001-09-11 Elpatronic Ag Seam welding method and apparatus
GB2379675A (en) * 2001-09-14 2003-03-19 Simon Palmer Prefabricated separating (party) floor
EP1057579B1 (fr) * 1999-05-26 2003-07-30 Sat Spa Dispositif de soudage au laser bord-à-bord de tôles (ébauches coupées sur mesure), ayant des rouleaux magnétiques pour mouvoir les tôles vers la position de soudage et des mors actifs pour serrer les tôles
US20040200172A1 (en) * 2003-04-14 2004-10-14 Beck John R. Building construction systems and methods

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3962773A (en) * 1972-09-19 1976-06-15 Lely Cornelis V D Methods for the manufacture of prefabricated building sections or room units and factories for the implementation of such methods
US4485608A (en) * 1982-07-13 1984-12-04 Restroom Facilities Corporation Prefabricated, self-contained building and method of construction
US5074457A (en) * 1988-08-11 1991-12-24 Fuji Photo Film Co., Ltd. Method and apparatus for splicing metal webs
US5123587A (en) * 1991-06-11 1992-06-23 Owen Joist Corporation Method and apparatus for making steel joists
US6288355B1 (en) * 1996-04-22 2001-09-11 Elpatronic Ag Seam welding method and apparatus
EP1057579B1 (fr) * 1999-05-26 2003-07-30 Sat Spa Dispositif de soudage au laser bord-à-bord de tôles (ébauches coupées sur mesure), ayant des rouleaux magnétiques pour mouvoir les tôles vers la position de soudage et des mors actifs pour serrer les tôles
GB2379675A (en) * 2001-09-14 2003-03-19 Simon Palmer Prefabricated separating (party) floor
US20040200172A1 (en) * 2003-04-14 2004-10-14 Beck John R. Building construction systems and methods

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116950421A (zh) * 2023-09-06 2023-10-27 刘诗琪 一种装配式建筑施工工艺

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