Log making apparatus

Abstract

A log making apparatus 1 comprises a tube support 200 configured to releasably hold a tube 100, the tube having a longitudinal axis and ends. A hole forming unit 300 is configured to form a pair of ho

Description

Technical Field

[0001] The present invention relates to a log making apparatus and a system for manufacturing logs. Background

[0002] There are many challenges associated with building a structure (such as a house) in a remote location. Providing building equipment, building materials and a construction crew to a remote location may be challenging, due to the time and resources required in transporting heavy machinery, heavy building materials and construction crew to a building site. These challenges may be exacerbated in areas that are difficult to reach, such as remote areas in a mountain range, or a plantation far away easy-to-access transport. There are also challenges in providing building equipment, building materials and a construction crew to areas affected by natural disasters, such as earthquakes. Such areas may be in particular need of new housing on a short time scale, while facing unexpected shortages of building equipment, building materials and construction crew.

[0003] According to US 9,863,142, there is provided an example of a freestanding structure which may be constructed from a plurality of metalogs. The metalogs are hollow logs, such as hollow steel logs, which can be stacked together to form a free-standing wall or building. The metalogs may be connected to each other by connector elements. This structure is relatively easy to assemble when a kit comprising a plurality of metalogs and connector elements is provided. While a kit comprising metalogs and connector elements of US 9,863,142 is lighter than conventional building equipment and building materials, transportation of metalogs and connector elements to a remote location is still a cumbersome process. A structure built from metalogs and connector elements according to US 9,863,142 is shown schematically in Figure 1. Problem to Be Solved

[0004] There is a need to provide a transportable system which can make parts for easy assembly of a structure, such as a building. Summary

[0005] According to the present invention there is provided a log making apparatus comprising: a tube support configured to releasably hold a tube, the tube having a longitudinal axis and ends;

[0006] a hole forming unit configured to form a pair of holes set at a location spaced apart from the ends; a connector unit configured to attach a connector to an end of the tube; and a control unit configured to control the hole forming unit and the connector unit.

[0007] Optionally, the tube support comprises a support structure and a tube fixing device.

[0008] Optionally, the tube fixing device is further configured to move relative to the support structure along a longitudinal axis of the support structure and / or perpendicular to the support structure longitudinal axis.

[0009] Optionally, the support structure comprises two or more lateral rails extending substantially parallel to a longitudinal axis of the tube support.

[0010] Optionally, the hole forming unit is configured to move relative to the support structure.

[0011] Optionally, the tube fixing device comprises two or more holders on opposite sides of the longitudinal axis of the tube support, the holders being configured to releasably fix the tube, optionally wherein each holder comprises a padded surface for holding the tube.

[0012] Optionally, at least one holder has a hole disposed therein.

[0013] Optionally, the hole forming unit comprises at least two drills disposed on opposite sides of a longitudinal axis of the tube support.

[0014] Optionally, the hole forming unit comprises at least two drills disposed on opposite sides of a longitudinal axis of the tube support; the tube support comprises two or more holders on opposite sides of the longitudinal axis of the tube support, the holders configured to releasably fix the tube, the number of holders being equal to the number of drills, optionally wherein each holder comprises a padded surface for holding the tube, wherein the two or more holders have a hole disposed therein, and each of the at least two drills is configured to perforate the tube through a respective hole in the respective holder.

[0015] Optionally, the control unit is configured to actuate movement of the at least two drills simultaneously, such that the at least two drills perform a drilling operation to form the pair of holes.

[0016] Optionally, the pair of holes are in a surface of the tube in a plane substantially perpendicular to a longitudinal axis of the tube.

[0017] Optionally, the connector unit is configured to insert a connector into the end of the tube and to release the connector when positioned in the tube for attaching the connector to the tube.

[0018] Optionally, the connector unit is configured to elastically deform the connector prior to inserting the connector into the end of the tube.

[0019] Optionally, the connector unit is configured to clamp the connector onto the end of the tube by plastically deforming at least part of the connector.

[0020] Optionally, the connector unit is configured to clamp the connector and the hole forming unit is configured to form the holes simultaneously.

[0021] Optionally, the tube support comprises an extendable tube support section, wherein a longitudinal axis of the extendable tube support section aligns with a longitudinal axis of the tube support, optionally wherein the extendable tube support section is supported by a wheel.

[0022] Optionally, the log making apparatus further comprising a container, wherein the tube support, the hole forming unit and the connector unit are disposed in the container, wherein the container comprises a base, a roof and four walls, wherein optionally, the container is portable; and wherein the tube support comprises an extendable tube support section, wherein a longitudinal axis of the extendable tube support section aligns with a longitudinal axis of the tube support, optionally wherein the extendable tube support section is supported by a wheel.

[0023] Optionally, a length of the extended tube support is greater than a longitudinal length of the container.

[0024] Optionally, the log making apparatus further comprises a container, wherein the tube support, the hole forming unit and the connector unit are disposed in the container, wherein the container comprises a base, a roof and four walls, wherein optionally, the container is portable.

[0025] Optionally, at least one wall comprises a removeable panel.

[0026] Optionally, the container comprises one or more hooks on an outer surface configured such that the container may be lifted.

[0027] Optionally, the log making apparatus, comprises a plurality of tube supports, which are substantially parallel and configured to support respective tubes.

[0028] Optionally, each of the plurality of tube supports has a corresponding hole forming unit and connector unit.

[0029] According to the present invention, there is provided a system for manufacturing logs comprising: a tube forming unit configured to form a tube from a sheet of metal, and the log making apparatus.

[0030] According to the present invention, there is provided a method of manufacturing a log, comprising: holding a tube with a tube support, the tube having a longitudinal axis and ends;

[0031] forming a pair of holes at a location spaced apart from the ends via a hole forming unit; attaching a connector to an end of tube via a connector unit.

[0032] Optionally, the method manufactures the log using the apparatus of any one of claims 1 to 23. Brief Description of the Drawings

[0033] Exemplar}- embodiments of the invention are described below with reference to the accompanying figures, in which:

[0034] Figure 1 is a schematic of a structure according to the prior art.

[0035] Figure 2A is a schematic of an end of a tube and a connector prior to the connector being attached to the tube. Figure 2B is a schematic of the end of the tube and the connector during the connector being attached to the tube, the connector being elastically deformed by a connector unit according to the present disclosure. Figure 2C is a schematic of a connector being attached to a tube, after a connector unit attaches the connector to the end of the tube.

[0036] Figure 3 is a schematic cross-section of an example of three logs formed by a log making apparatus according to the present disclosure, the logs having a stiffener extending through a pair of holes in each log, the pair of holes being at diametrically positions of each log.

[0037] Figure 4 is a top view of portion of a log formed by a log making apparatus according to a present disclosure, the log comprising holes at diametrically opposite positions.

[0038] Figure 5 is a schematic cross-section of an example of three logs formed by a log making apparatus according to the present disclosure, the logs having a stiffener extending through a pair of holes in each log, the pair of holes being displaced from diametrically opposite positions of each log.

[0039] Figure 6 is a top view of a portion of a log formed by a log making apparatus according to a present disclosure, the log comprising holes which are displaced from diametrically opposite positions.

[0040] Figure 7 shows a log making apparatus according to the present disclosure.

[0041] Figure 8A is a schematic cross-section of a log making apparatus according to the present disclosure, showing a tube fixing device in a fixing position. Figure 8B is a schematic crosssection of a log making apparatus according to the present disclosure, showing a tube fixing device in a released position.

[0042] Figure 9 is a schematic isometric view of part of a tube fixing device and hole forming unit according to the present disclosure.

[0043] Figure 10 is a schematic cross-section view of a connector unit and tube, prior to a clamping step being performed.

[0044] Figure 11 is a schematic cross-section view of a tube, after a clamping step has been performed.

[0045] Figure 12A is a close-up schematic cross-section view of a connector and tube as shown in Figure 10, prior to a clamping step being performed. Figure 12B is a close-up schematic crosssection view of a connector and tube as shown in Figure 11, after a clamping step has been performed.

[0046] Figures 13A, 13B and 13C show a log making apparatus according to the present disclosure.

[0047] Figure 14 is a schematic of a container according to the present disclosure.

[0048] Figure 15 is a schematic of a container according to the present disclosure.

[0049] Figure 16 is a schematic of a log making apparatus according to the present disclosure, wherein the container is in an open state.

[0050] Figure 17 is a schematic of a log making apparatus according to the present disclosure, wherein the container is in an open state.

[0051] In the various figures, like parts are denoted by like references. Detailed Description

[0052] To clarify the invention, a Cartesian coordinate system is used. The Cartesian coordinate system has three axis, i.e., an x-axis, a y-axis and a z-axis. Each of the three axis is orthogonal to the other two axis.

[0053] In the figures, a longitudinal axis of the tube is the X-axis.

[0054] According to the present disclosure, a tube 100 is a hollow tube. In a preferable embodiment, the tube 100 may have a cylindrical shape, i.e. having a circular cross-section. In an alternative embodiment, the tube 100 may have a non-circular cross-section, such as an oval or a square.

[0055] According to the present disclosure, a connector is a component which may be attached to an end of the tube 100, the connectors configured such that they can be attached to other connectors. A tube 100 having a connector attached to an end thereof may be referred to as a log. The log may comprise a tube 100 with a connector disposed in each end of the tube 100. The log may have holes (e.g. for stiffeners) as described below. Logs can be stacked together such that the connector of one log engages with a connector of another log, such that a freestanding structure is formed. Tire logs may otherwise be referred to as metalogs.

[0056] An example of a connector 402 is shown in Figures 2A-2C. The features of example connector 402 are described in detail in US 4,619,089. The contents of US 4,619,089 is incorporated by reference in their entirety. The connectors may have an insertion portion (which is attachable to a tube) and a protruding portion (which protrudes from the log and can interlock with protruding portions of other connectors to form a structure). The protruding portion may have a cross-section (taken through the connector perpendicular to a longitudinal axis of the tube when the connector is attached to the tube) which has a maximum dimension that is the same as the diameter of the tube. Alternatively, the maximum dimension may be greater than the diameter of the tube.

[0057] According to the present disclosure, a log (i.e. a metalog) is a component which is ready for assembly into a structure, as shown in Figure 1. An example of a structure which can be formed from logs is disclosed in US 9,863,142 (and shown in Figure 1), which is herein incorporated by reference in its entirety. The logs are stacked into a structure, such that the end connectors of logs interlock with connectors of other logs.

[0058] A log may have a plurality of holes disposed on an outer surface. Each hole is a through-hole. The holes may be provided as pairs (referred to as pair of holes 24). Each hole of the tube 100 may have at least one other hole disposed on an opposite side of the tube 100, relative to the longitudinal axis of the tube 100 (i.e. said hole pair defines the diameter of a circular cross section of the tube). Thus, the holes may be diametrically opposite. Ure holes can be configured such that a stiffener 22 may be inserted into the hole pair, such that the stiffener 22 extends along an axis perpendicular to the longitudinal axis of the tube 100. For a given set of tubes 100 which are to fonn a structure, it is preferable that the pair of holes 24 of each of the set of tubes 100 are in the same position, so that a stiffener 22 may be passed through once the structure is assembled. If the pairs of holes 24 of at least one tube in the set of tubes 100 is displaced relative to the position of other pairs of holes 24, it may not be possible to pass stiffener 22 through the pairs of holes.

[0059] As shown in the example in Figure 3 and Figure 4, the log may comprise a pair of holes 24 in its surface. The log may have multiple pairs of holes 24 which are spaced apart as shown in Figures 4 and 6. The pairs of holes of several logs are preferably aligned along the longitudinal length of the log so that the logs can be stacked as shown in Figures 4 and 6, and a stiffener 22 can be passed through the aligned holes. In any given log, the pair of holes are preferably at diametrically opposite locations (as shown in Figures 3 and 4). Alternatively, the pair of holes maybe displaced from diametrically opposite positions (as shown in Figure 5 and Figure 6). When the pairs of holes are displaced from diametrically opposite positions, the holes of the logs can still be aligned as shown in Figure 5. A structure formed from logs having the pair of holes, the connector(s) and the stiffener(s) is described in US patent 9,963,142 (incorporated herein in its entirety, as above).

[0060] According to the present disclosure, there is provided a log making apparatus 1 which is configured to make logs, such as the logs described above. A log making apparatus 1 according to the present disclosure is shown in Figure 7.

[0061] According to the present disclosure, there is provided is log making apparatus 1 comprising: a tube support 200 configured to releasably hold a tube 100, the tube 100 having a longitudinal axis and ends; a hole forming unit 300 configured to form a pair of holes set at a location spaced apart from tine ends; a connector unit 400 configured to attach a connector to an end of the tube 100; and a control unit 500 configured to control the hole forming unit 300 and the connector unit 400. hi an embodiment, the control unit 500 is configured to control the tube support, or at least part of the tube support.

[0062] The tube support 200 may support a tube 100 along a longitudinal axis of the tube 100. In other words, the tube support 200 may support the tube 100 along its length. For example, the tube 100 may lie horizontally on the tube support 200 (e.g. along the x-axis shown in figure 8). The tube 100 may be held in place by the tube support 200. The tube support 200 may support a tube 100 along a longitudinal axis of the tube support 200. The longitudinal axis of the tube support 200 may be substantially parallel to the longitudinal axis of the tube 100. hr an example, the tube support 200 may support a tube which is 0.4 to 12 m in length. Preferably, the tube support 200 may support atube which is 4 to 4.5 m in length. The tube support may be 0.5 to 13 m long along its longitudinal axis, or 5 to 7 m in length along its longitudinal axis.

[0063] Figure 7 shows two log making apparatuses side by side. Components of the log making apparatus 1 on the right hand side are connected to the control unit by means of wiring 501. Components of the log making apparatus 1 on the left hand side are also connected to the control unit 500 by means of wiring which is hidden.

[0064] Components of the log making apparatus 1 may be connected to a control unit 500 by wireless means, meaning that that wiring 501 is not required for a control unit 500 to be connected to a hole forming unit 300 and connector unit 400.

[0065] Components of the log making apparatus 1 connected to the control unit 500 include any combination of the tube support 200, the hole forming unit 300, and the connector unit 400. Preferably, all of the tube support, hole forming unit and connector unit are connected to the control unit.

[0066] The control unit 500 may comprise several controllers, for example, one controller for a hole forming unit and / or one controller for a connector unit and / or one controller for the connector unit, where the controllers are configured to communicate with each other.

[0067] The log making apparatus 1 according to the present disclosure is easily transportable, as it comprises relatively few components. According to the prior art, making logs is a cumbersome process, because the pair of holes have to be formed manually. It may be particularly difficult to form a pair of facing holes when operating in a remote location. Furthermore, according to the prior art, there is no known convenient way of inserting the connectors into the ends of the tube 100.

[0068] According to the present invention, the pair of holes is formed by a hole forming unit and the connector is attached to an end of the tube by a connector unit. Therefore, a log can be made by the log making apparatus 1, reducing the level of user intervention required.

[0069] The control unit is configured to control at least the hole forming unit 300 and the connector unit 400, which means that a log can be formed by the log making apparatus 1 remotely with reduced user intervention.

[0070] The tube support 200 may comprise a tube fixing device 201 and a support structure 210. The support structure 210 may be a stationary portion (i.e. does not move during use). The tube fixing device 201 may be moveable relative to a support structure 210.

[0071] The tube fixing device 201 may be further configured to move relative to the support structure 210 along a longitudinal axis of the support structure. The support structure 201 may comprise two or more lateral rails 204 extending substantially parallel to the longitudinal axis of the tube support 200. The tube fixing device 202 may move along the lateral rails 204 (i.e. parallel to / along the longitudinal axis of the support structure) such that the tube 100 may be fixed by the fixing device 202 at an appropriate location of the tube 100. The position and / or movement of the fixing device 202 along the lateral rails 204 may be controlled by the control unit.

[0072] Lateral rails 204 may be provided with markers disposed at predetermined intervals. The predetermined intervals are not particularly limited and may be 3 cm, 5 cm , 7 cm, 10 cm, or another value. Providing markers may aid a user when aligning the tube fixing device and / or other components along the lateral rails 204. The markers may be perforations along the lateral rails 204. The tube fixing device 201 may comprise a protrusion which may releasably engage with said perforation to releasably secure the tube fixing device 201 in place.

[0073] Additionally or alternatively, the tube fixing device 201 may be further configured to move relative to the support structure 210 perpendicular to the support structure longitudinal axis. For example, the tube fixing device 201 may be moved in a plane perpendicular to the longitudinal axis of the support structure. More specifically, the tube fixing device 201 may be rotated about one of the lateral rails 204.

[0074] The hole forming unit 300 may be configured to move relative to the support structure 201, for example, along the lateral rails 204. As mentioned previously, the support structure 201 may be a stationary part of the tube support 200. For example, the hole forming unit 300 may travel along the lateral rails 204 to the appropriate position to form holes in the tube 100.

[0075] As mentioned previously, high accuracy in formation of the hole pair is advantageous. This is because accurate hole pair formation in each one of a set of tubes 100 may enable a stiffener 22 to be passed through the holes once a structure is assembled from the set of tubes 100. Providing lateral rails 204 with markers as mentioned previously may be particularly advantageous for accurate alignments of the hole forming unit 300 along the lateral rails.

[0076] Reference is now made to Figures 8A and 8B. Figure 8A shows a cross-section of the tube fixing device 202 and the hole formation unit 300 when tube 100 is fixed by the tube support 200 in a fixing position. Figure 8B shows a cross-section of the tube fixing device 202 and the hole formation unit 300 when the tube fixing device 202 is in a released position.

[0077] The tube fixing device 202 may comprise two or more pad holders 202 on opposite sides of the longitudinal axis of the tube support, the pad holders 202 being configured to releasably fix the tube 100. Fixing the tube 100 in place ensures that the tube 100 does not move during a clamping operation and / or a perforation operation (i.e. hole forming operation). In Figure 8, pad holders 202 are shown pressing on opposite sides of the tube 100. The tube 100 is therefore fixed in place relative to a log making apparatus 1 by tube fixing device 202. Two pad holders 202 may be provided as a pad holder pair, with each pad holder on opposite sides of the tube 100. The fixing device 202 may comprise multiple pad holder pairs which can be positioned along the length of the tube 100, and which may be used to hold different parts of the tube 100 in place at the same time. While reference is made to Figure 8A, the tube fixing device 202 may comprise two or more pad holders 202 in all embodiments of the invention.

[0078] The tube fixing device 202 is configured to hold the tube 100 m place during a log formation step. The tube fixing device 202 may move between a fixing position (in which the tube is fixed in place, as shown in Figure 8A) and a released position (in which the tube is free to move, as shown in Figure 8B). The hole forming unit 300 is not shown on Figure 8B.

[0079] The tube fixing device 202 may change from a fixing position and a released position by rotational movement of the tube fixing device 202 (such as pad holders 202) relative to lateral rail 204. The movement from a released position (as in Fig. 8B) to a fixing position (as in Fig. 8A) is shown schematically by arrows A on Figure 8B. In other words, the tube fixing device may pivot about lateral rails 204 between a fixing position and a released position.

[0080] Reference is now made to Figure 9. At least one pad holder 202 may have a hole 203 disposed therein. Alternatively, the two or more pad holders 202 may each have a hole 203 disposed in each pad holder 202. Preferably, each pad holder has a hole 203. The hole forming unit 300 and the tube fixing device 203 may be configured such that the hole forming unit 300 forms a hole in the tube 100 through hole 203, when the tube fixing device 202 is in a fixing position. This may improve the accuracy of a perforation step (i.e. a hole being formed in the tube 100), as hole 203 of the holder pad 202 acts as a guide.

[0081] Figures 8A and 8B show holders 202 each having hole 203 disposed therein, however, each of or one of the holders 202 shown in Figures 8A and 8B may be provided without hole 203.

[0082] The hole forming unit 300 may comprise at least two drills 303 disposed on opposite sides of a longitudinal axis of the tube support. In other words, the at least two drills 303 may be disposed on diametrically opposite locations, configured to form a pair of diametrically opposite holes in tube 100. Alternatively, the drills 303 may be displaced from diametrically opposite locations, configured to form a pair of holes which are displaced from diametrically opposite positions in tube 100. The drills 303 may be connected to, and movable along, the lateral rails 204. The position and / or movement of the drills 303 along the lateral rails 204 may be controlled by the control unit 500.

[0083] The hole forming unit 300 be configured to travel perpendicular to a longitudinal axis of the tube support during a hole forming step. The hole forming unit may travel perpendicular to a longitudinal axis of the tube support by travelling along hole forming unit rails 302 (HFU rails 302). This movement is shown schematically by arrows B on Figure 8. Accordingly, hole forming unit 300 may be moved towards tube 100 such that hole forming unit 300 may form a pair of holes in the tube 100. Once a hole forming step has been completed by hole forming unit 300, the hole forming unit 300 may be retracted from the tube 100. The position and / or movement of the hole forming unit 300 along the HFU rails 302 may be controlled by the control unit. A sensor may be provided which can detect that a hole forming operation has been completed. The sensor may determine that a hole forming operation has been completed based on the position of the hole forming unit 300 relative to the tube 100.

[0084] HFU rails 302 may be connected to the tube fixing device 202, such that the HFU rails and fixing device 202 move together with the tube fixing device 202. The HFU rails 302 may be provided integrally with the tube fixing device 202. In this embodiment, when a tube fixing device 202 is moved to a fixing position, HFU rails 302 are also moved. Accordingly, HFU rails are configured such that when tube fixing device 202 is in the fixing position, the hole forming unit 300 is in the appropriate position where the hole forming unit 300 can form a pair of holes (e.g. by moving the drills along the HFU rails 302).

[0085] In the examples in Figures 8A and 9, the HFU rails 302 would be parallel to the Z axis when the hole forming unit is positioned to form the holes (in a fixing position). Accordingly, the drills can be moved along the same axis in opposite directions to form a pair of holes 24 in the tube 100 which face each other, e.g. to form a diametrically opposite pair of holes. The HFU rails 302 may be positioned elsewhere, e.g. the HFU rails may be perpendicular to a surface of the tube 100 at positioned which are displaced from being diametrically opposite, e.g. to form holes as shown in Figures 5 and 6. According to this embodiment, the speed of a hole forming operation may be increased, as the drills 303 may be moved towards the tube 100 immediately after the tube fixing device 202 is in a fixing position.

[0086] The pad holders 202 may comprise a padded surface for holding the tube. More specifically, the pad holders 202 may comprise pads configured to conform to a shape of tube 100, so that tube 100 can be fixed in place by pads pressing on tube 100. This may be advantageous in reducing the likelihood of damaging the tube, whilst keeping the tube 100 in place. However, the pads may not exactly conform to a shape of tube 100. While the example log making apparatus 1 shown on Figure 7 shows that pad holders 202, any suitable tube fixing device may be used.

[0087] A pad holder 202 may comprises a padded surface for holding the tube. However, the tube fixing device may comprise any suitable holder 202 instead of the pad holder 202, wherein holder 202 does not comprise a padded surface. Holder 202 without a pad may replace a pad holder as described in any of the variations of the log making apparatus 1.

[0088] At least one pad holders 202 may comprise a hole 203 disposed therein. The hole forming unit may be configured such that it forms a hole in tube 100 in an area defined by hole 203 when the tube fixing device 202 is in a fixing position. For example, drill 303 may be aligned with hole 203, as shown on Figure 9.

[0089] Some pad holders 202 may be provided without a hole 203 disposed therein. Such pad holders may be provided along the length of the tube support 200, to provide additional support to the tube 100 when it is fixed. Some or all of the pad holders 202 may be provided without a hole 203 disposed therein, because the hole forming unit 300 may be configured to form holes in the tube 100 without the need for hole 203.

[0090] The tube support 200 may comprise two or more pad holders 202 on opposite sides of the longitudinal axis of the tube support 200, the pad holders 202 configured to releasably hold the tube 100, the number of pad holders being equal to the number of drills 303, wherein the two or more pad holders 202 have a hole 203 disposed therein, and each of the at least two drills 303 is configured to perforate the tube 100 through a respective hole in the respective pad. hi an embodiment, there is an even number of pad holders 202, the pad holders positioned facing each other, so that they may fix the tube 100 in a fixing position by pressing on opposite sides of tube 100.

[0091] When the two or more pad holders 202 are moved to the fixing position, the holes 203 provide a guide for the drills 303 which perforate the tube 100 through a respective hole in the respective pad. Furthermore, performing a hole forming operation at the hole 203 is less likely to cause tube 100 to bend along its axis, compared to a situation where a hole forming operation on a region of tube 100 which is removed from the pad holder 202. Accordingly, performing a holder forming operation through a hole 203 improves the efficiency and accuracy of the hole forming operation.

[0092] The pad holder 202 may not have a hole 203 disposed therein. For example, the pad holder may be provided in a different configuration which is above and / or below the location for forming the hole on the tube. Additionally or alternatively, the pad holder may comprise a slit or opening through which the hole forming apparatus can form the hole in the tube.

[0093] The control unit 500 may be configured to actuate movement of the at least two drills 303 simultaneously, such that the at least two drills perform a drilling operation to form the pair of holes. Although this is not a necessity, as each of the drills may be controlled independently.

[0094] In an embodiment, the pair of holes 24 are in a surface of the tube 100 in a plane substantially perpendicular to a longitudinal axis of the tube. The holes are preferably at diametrically opposite locations (e.g. as shown in Figure 3). However, in an embodiment, the holes may be displaced from diametrically opposite positions (as shown in Figure 5).

[0095] The control unit 500 may be configured to actuate movement of the at least two drills 303 along HFU rails 302 simultaneously, such that the at least two drills perform a drilling operation to form the pair of holes at the same time. Accordingly, efficiency of the log making apparatus 1 may be improved. Alternatively, the two drills 303 may be actuated one at a time.

[0096] The control unit 500 may be configured to control movement of the at least two drills along the HFU rails 302 and optionally, along the lateral rails 204. Accordingly, movement of tire drills may be controlled so that the drills may move in a predetermined manner.

[0097] The connector unit 400 may move along lateral rails 204. The connector unit 400 may be moved to a first position, in which it is disposed such that a user may place a tube 100 onto the tube support 200 without interfering with the connector unit 400. The connector unit 400 may be moved to a second position, in which it engages with a connector 402, such that it may attach the connector 403 to the tube end as described.

[0098] The connector unit 400 may be configured to insert a connector 402 into the end of the tube 100 and then to release the connector 402. A user may place connector 402 on the tube support 200 such that the connector 402 is along the longitudinal axis of tube 100, and may optionally perform a manual insertion operation. The performing of manual insertion of connector 402 into the end of the tube may only partially insert the connector 402 into the tube. The connector unit 400 may then perform a further automatic insertion operation on the connector 402 such that the connector 402 may be attached to the tube 100. Alternatively, insertion of the connector 402 into the end of the tube may be fully manual or fully automatic. The connector 402 may be placed on tube support 200 by automatic means, such as a crane for example (not shown).

[0099] The log making apparatus 1 may comprise two connector units 400 disposed at either end of the longitudinal axis of the tube support 200, each of which is configured to attach a connector to a respective end of tube 100.

[0100] Movement of one or more of the connector unit 400, the hole forming unit 300 and the tube fixing device 202 may be powered by a pneumatic system. According to this embodiment, the one or more of the connector unit 400, the hole forming unit 300 and the tube fixing device 202 may be provided with tubes which control movement of each component. The log making apparatus 1 may comprise an air compressor which powers the pneumatic system.

[0101] Alternatively, movement of one or more of the connector unit 400, the hole forming unit 300 and the tube fixing device 202 may be powered by a different means, such as a hydraulic system.

[0102] The connector unit may be configured to elastically deform the connector 402 prior to the inserting the connector into the end of the tube. An example of this is shown on Figures 2A-2C. Figure 2B shows that a connector 402 is elastically deformed such that can fit inside the end of the tube. When the connector 402 is released, the connector 402 returns to its mostly undeformed state. The tube circumference prevents the connector 402 from relaxing fully, meaning that an interference fit is formed. The example shown on Figures 2A-2C is not limiting, and any connector shape may be used.

[0103] The connector unit 500 may be configured to insert a connector 402 into an end of the tube to form an interference fit. Accordingly, a connector may be connected (fastened) to the end of the tube by a joint which is held together by friction.

[0104] Alternatively or additionally, after insertion of the connector (manually or by the connector unit), the connector unit 400 may be further configured to attach the connector 402 to an end of the tube. The connector unit may be configured to clamp the connector onto the end of the tube by plastically deforming at least part of the connector. This is explained with reference to Figures 10, 11, 12A and 12B.

[0105] The connector unit 400 may comprise a clamping member 400a configured to engage with an edge of a connector 402 to attach a connector 402 to an edge of tube 100.

[0106] The connector unit may 400 be configured to clamp an end portion of the tube to form a connection with the connector 402 (e.g. as shown schematically in the cross-sections in Figures 10 and 11). In other words, the connector unit may be used to crimp an end portion of the tube to form a connection with the connector.

[0107] The clamping member 400a may comprise a pair of gripping jaws, wherein one or more of the jaws may be pivoted around a pivot point. In the embodiment on Figure 10, one of the jaws is pivotable around a pivot point 400b.

[0108] As shown on Figure 10, the connector 402 may have at least two U-portions 402a both of which are configured to fit around an edge of tube 100. The clamping member 400a may be configured such that it may perform a clamping operation on a tube 100 having a connector fitted to an end thereof. hi other words, the clamping member 400a may comprise gripping jaws which may deform a connector 402 such that it engages with the end of tube 100.

[0109] The number of clamping members 402a may correspond to the number of U-portions 402a of a connector 402.

[0110] In an example, the connector unit may comprise four clamping members 400a each of which can perform a clamping operation on a respective U-portions 402a of a connector 402. This configuration may be particularly preferable for performing clamping on a connector having four U-portions 402a. When a clamping operation is performed by connector unit 400, the clamping member 400a is configured to deform U-portions 402a of the connector 400 around an edge of the tube to form a join 402b, as shown on Figure 11. This is one example of a connection being formed between a connector 402 and the tube 100.

[0111] Alternatively or additionally, the connector unit 400 may be configured to plastically deform an end portion of the tube 100 to form a connection between connector 402 and tube 100.

[0112] A clamping operation of each of the one or more clamping members 402a may be configured such that the U-portions of the connector plastically deform the tube 100. hr an example, the clamping members 402a may be deformed such that part of the U-portion forms a depression in the tube 100 thereby securing the connector 402 to tube 100.

[0113] A close up of the U-portion 402a and the tube 100 is shown on Figure 12A. A close-up of the join 402b formed between the tube and the connector is shown on Figure 12B.

[0114] The connector may be any suitable shape which can interlock with other connectors, such as the connector 402 shown on Figures 2A-2C.

[0115] In the cross sections shown on Figures 10 and 11, two clamping members 400a can be seen. However, one or more further clamping members 400a may be provided disposed around the longitudinal axis of the tube support 200 (i.e. around the circumference of the connector / tube). For example, four clamping member 400a may be provided, preferably disposed at 90 ° intervals, around the tube support longitudinal axis, each clamping member 400a disposed such that each of the clamping members 400a are equidistant from a centre of a tube 100 when tube 100 is support by the tube support 200.

[0116] The connector unit 400 may be configured to clamp the connector 402 and the hole forming unit 300 is configured to form the pair of holes simultaneously.

[0117] An example of a log making apparatus 1 according to the present disclosure is shown on Figures 13A-13C. Figure 13A shows a log making apparatus 1 prior to a log making operation. Connector 402 is inserted into a tube 100 such that U-portions 402a engage with an end of tube 100. The tube fixing device 202 and hole forming unit 300 are moved along the lateral rails 204 until the tube fixing device 202 and hole forming unit 300 are aligned with the area of the tube 100 where a hole is to be made (i.e. where a perforation step / hole forming operation is to be performed). Once alignment of the is tube fixing device 202 and hole forming unit 300 is complete, the tube fixing device 200 is moved to a fixing position, i.e. pad holders 202 are engaged with the tube such that the tube is fixed in place (only one pad holder 202 is shown on Figures 13A-13C).

[0118] Figure 13B shows a log making apparatus 1 during a log making operation. Connector unit moves parallel to the tube support longitudinal axis such that the clamping members 400a engage with the U-portions 402a of the connector (or such that the connector unit 400 may attach connector 402 by the relevant means, such as elastic deformation discussed above). A clamping operation is performed to plastically deform U-potions 402a to form joins 402b. A perforation operation is performed by hole forming unit 300, preferably but not necessarily simultaneously, such that a pair of aligned holes is formed in the tube 100 spaced apart from the ends.

[0119] Figure 13C shows a log making apparatus 1 after a log making operation. Once join 402b is formed, connector unit 400 moves away from the tube 100 along the X-axis.

[0120] After connector unit 400 moves away from the tube 100, the hole forming unit 300 moves away along HFU rails 302 and the tube fixing device 202 moves away by rotational movement of the tube fixing device 202 about lateral rail 204. The connector unit 400, hole forming unit 300 and tube fixing device 202 may be moved independently. For example, the connector unit 400 may be moved first to attach the connector 402 to an end of the tube 100. After the connector 402 has been attached, the tube fixing device 202 may be moved to secure the tube 100 in place before a hole forming operation is performed. After the tube 100 is secured in place by the tube fixing device 202, the hole forming unit 300 may form a pair of holes in the tube 100. The hole forming unit 300 may then be moved away from the tube 100, followed by the tube fixing device 202 releasing the tube 100. The connector units 400 may then be moved such that a tube 100 one or more pairs of holes formed therein and having one or more connectors attached (i.e. the log) may be removed from the tube support 200 by the user. When two connector units 400 are provided at each end of the longitudinal axis of the tube support 202, these may move simultaneously. When multiple tube fixing devices 202 are provided along the length of the tube 100, these may move simultaneously. When multiple hole forming units 300 are provided along the length of the tube 100, these may move simultaneously.

[0121] Accordingly, the connector 402 is connected and a pair of holes are formed in tube 100 with the log making apparatus 1. Thus, a log is formed.

[0122] Reference is now made to Figure 14, Figure 15, Figure 16 and Figure 17.

[0123] In an embodiment, the tube support 200, the tube fixing device 201, the hole forming unit 300 and the connector unit 400 are disposed in a container 900, wherein the container 900 comprises a base 601, a roof 600 and four walls, wherein optionally, the container is portable. Accordingly, the of the transporting apparatus can be easily transported in the container. The control unit is not necessarily disposed in the container. For example, the control unit 500 may be disposed off-site and control the log making apparatus 1 components via wireless communication. The air compressor, if provided, may be disposed in the container 900, so that it may be transported together with other components of the log making apparatus 1.

[0124] In an example, the longitudinal axis of the tube support 200 is substantially parallel to two wall surfaces of the container.

[0125] At least one wall may comprise a removeable panel 700. The container may comprise pillars 701 which support the roof 600 when one or more removeable panel 700 is removed. The panel may be a substantial part of, or substantially the entire, wall. Thus, one of the walls may be removed once the log making apparatus 1 is provided on a site for manufacturing logs. This may improve the convenience of accessing the components of the log making apparatus 1 disposed inside container 900 during log making. For example, once the log making apparatus 1 arrives at the designated location, the removeable panels 700 may be removed for ease of access to the apparatus.

[0126] The container 900 may comprise one or more hooks 901 on an outer surface configured such that the container may be lifted. The hooks 901 are preferably disposed on the roof 600. This enables the container to be lifted and moved by means of a crane, for example. This improves the transportability of the log making apparatus 1.

[0127] Additionally, or alternatively, the container 900 may be disposed on a vehicle. Accordingly, the container 900 and the components disposed therein may be easily transported to a remote location. According to this embodiment, the container may have an extendable platform at its base, wherein the platform may support the weight of multiple workers (e.g. the platform may support 1 tonne to 5 tonnes in weight). The platform may surround the container 900, such that workers may walk on the base and easily access tire components inside the container. The container 900 may be welded to the vehicle, so that the container 900 may be easily transported.

[0128] The tube support 200 may comprise an extendable tube support section 210, wherein a longitudinal axis of the extendable tube support 210 section aligns with a longitudinal axis of the tube support 200. The extendable tube support section 210 may support tube 100, thereby extending the longitudinal length of the tube support 200, meaning that a longer tube 100 may be supported. This is advantageous, because the tube support 200 may be kept relatively short for short tubes 100, and extended for supporting longer tubes 100. The log making apparatus 1 may comprise the extendable tube support section 210 disposed within container 900. Alternatively, the extendable tube support section 210 may be provided in an embodiment of the disclosure which does not comprise a container 900.

[0129] The extendable tube support section 201 may be extended as follows. As shown in an example on Figure 17, the extendable tube support section 210 may be stored above the tube support 200 in a storage position, when it is not in use. This may be a particularly space efficient way of storing and transporting the log making apparatus 1 which comprises an extendable tube support section 210. In use, the extendable tube support section 210 may be pulled out from its storage position to an operation position. This may be done by a user or automatic means. In the operation position, the longitudinal axis of the extendable tube support section 210 aligns with the longitudinal axis of the tube support 200 (optionally, with the longitudinal axis of the support structure 201). While Figure 17 shows a container 900, the extendable tube support section may be extended as described above without the provision of a container 900.

[0130] An extendable tube support section 210 improves the transportability of the log making apparatus 1, which is important for a system which can be used at a remote location to make logs.

[0131] The log making apparatus 1 may comprise a container 900, wherein the tube support 200, the hole forming unit 300 and the connector unit 400 are disposed in the container 900, wherein the container 900 comprises a base 601, a roof 900 and four walls, wherein optionally, the container is portable; and wherein the tube support comprises an extendable tube support section, wherein a longitudinal axis of the extendable tube support section aligns with a longitudinal axis of the tube support, optionally wherein the extendable tube support section 210 is supported by a wheel 211. Accordingly, the extendable support section 210 may be wheeled out of container 900 when the tube support 200 needs to be extended. According to this embodiment, the extendable support section 210 is easily manoeuvrable.

[0132] The log making apparatus 1 may comprise the container 900, wherein one or more of the walls comprises the removeable panel 700. This may provide easier access to the contents of the container to allow parts of the logs, such as metal tubes, to be processed and removed from the apparatus more easily. The removable panel may be particularly useful when the tube support 200 comprises the extendable tube support 210.The removeable panel 700 may be removed such that the extendable tube support 210 extends outside of the base 601. The extendable tube support section 210 may be extended as described above, and the operation position of the extendable tube support section 210 is shown schematically on Figure 16.

[0133] In the operation position, the extendable tube support section 210 is supported by wheel 211. The wheel may be attached to the extendable tube support section 210, such that the wheel is moved from the storage position to the operation position along with the extendable tube support section 210. Hie wheel may be attached to the extendable tube support section 210 by a hinge. This may be a particularly convenient way of extending the longitudinal length of the tube support 200 to process longer logs 100.

[0134] According to this embodiment, the tube support 200 and the extendable tube support section 210 may be enclosed in a relatively short container 900. The container 900 may be transported to the area where log manufacture is required, the removeable panel 700 may be removed and the extendable tube support 210 may be extended through an opening in the wall left by the removeable panel 700. Accordingly, longer tubes 100 may be processed at a remote location which may not be possible without the extendable tube support 210.

[0135] While the extendable tube support section 210 being supported by wheel 211 is described with reference to an example of the invention comprising a container 900, the extendable tube support section 210 may be supported by the wheel 211 when the log making apparatus does not comprise a container 900.

[0136] A length of the extended tube support is greater than a longitudinal length of a container. Accordingly, a tube 100 which has a length longer than a length of un-extended tube support 200 may be supported and used to form a log.

[0137] In an example, a plurality of tube supports 200 may be provided, which are configured to support respective tubes and are preferably substantially parallel.

[0138] The plurality of tube supports 200 may have a corresponding hole forming unit 300 and connector unit 400. An example is shown on Figure 7, which shows two tube supports 200, each having a corresponding hole forming unit 300 and connector unit 400. The control unit 500 may be configured to control each of the corresponding hole forming units 300 and connector units 400, such that multiple logs may be formed at the same time.

[0139] According to the present disclosure, it is possible to quickly produce logs which may be used to form a structure. For example, in one hour, it is possible to make enough logs to form a house with a floor area of 50 m2.

[0140] According to the present disclosure, there is provided a system for manufacturing logs (e.g. a metalog) comprising: a tube forming unit configured to form a tube from a sheet of metal, and the log making apparatus 1 in any of the variations described above. The tube forming unit may be configured to form tube from a sheet of steel, for example.

[0141] The system may be used to form tubes and transform the tubes into logs by the log making apparatus 1, as described above. Accordingly, a structure such as a house may be built at a remote location by providing the system for manufacturing logs, a sheet of metal and a plurality of connectors. Transportation of the system for manufacturing logs, a sheet of metal and a plurality of connectors is a lot more convenient and inexpensive than transporting conventional building materials (such as bricks and cement). Reference numerals 1 Log making apparatus 22 Stiffener 24 Pair of Holes 100 Tube 200 Tube Support (may comprise 201 and 202) 201 Support Structure 202 Tube fixing device, such as pad holders 202 A (arrow) - movement on of tube fixing device 202 203 Hole (of tube fixing device) 204 Lateral Rail 210 extendable tube support section 211 Wheel 300 Hole Forming Unit B (arrow) - movement of hole forming unit 300 301 Wiring 302 Hole Forming Unit rail (HFU rail) 303 Drill 400 Connector Unit 400a Clamping Member 400b Pivot Point 402 Connector 402a U-portions (of connector) 402b Join 402 Connector (other embodiment) 500 Control Unit 600 Roof 601 Base 700 Removeable Panel 701 Column 900 Container 901 Hook

Claims

1. A log making apparatus comprising:a tube support configured to releasably hold a tube, the tube having a longitudinal axis and ends;a hole forming unit configured to form a pair of holes set at a location spaced apart from the ends;a connector unit configured to attach a connector to an end of the tube; and a control unit configured to control the hole forming unit and the connector unit.

2. The log making apparatus according to claim 1. wherein the tube support comprises a support structure and a tube fixing device.

3. The log making apparatus according to claim 2, wherein the tube fixing device is further configured to move relative to the support structure along a longitudinal axis of the support structure and / or perpendicular to the support structure longitudinal axis.

4. The log making apparatus according to any either of claims 2 or 3, wherein the support structure comprises two or more lateral rails extending substantially parallel to a longitudinal axis of the tube support.

5. The log making apparatus according to any of claims 2 to 4, wherein the hole forming unit is configured to move relative to the support structure.

6. The log making apparatus according to any one of claims 2 to 5, wherein the tube fixing device comprises two or more holders on opposite sides of the longitudinal axis of the tube support, the holders being configured to releasably fix the tube, optionally wherein each holder comprises a padded surface for holding the tube.

7. The log making apparatus according to claim 6, wherein at least one holder has a hole disposed therein.

8. The log making apparatus according to any of claims 1 to 7, the hole forming unit comprises at least two drills disposed on opposite sides of a longitudinal axis of the tube support.

9. The log making apparatus according to any of claims 1 to 5, wherein:the hole forming unit comprises at least two drills disposed on opposite sides of a longitudinal axis of the tube support;the tube support comprises two or more holders on opposite sides of the longitudinal axis of the tube support, the holders configured to releasably fix the tube, the number of holders being equal to the number of drills, optionally wherein each holder comprises a padded surface for holding the tube,wherein the two or more holders have a hole disposed therein, andeach of the at least two drills is configured to perforate the tube through a respective hole in the respective holder.

10. The log making apparatus according to either of claims 8 or 9, wherein the control unit is configured to actuate movement of the at least two drills simultaneously, such that the at least two drills perform a drilling operation to form the pair of holes.

11. The log making apparatus according to any of claims 1 to 10, wherein the pair of holes are in a surface of the tube in a plane substantially perpendicular to a longitudinal axis of the tube.

12. The log making apparatus according to any of claims 1 to 11, wherein the connector unit is configured to insert a connector into the end of the tube and to release the connector when positioned in the tube for attaching the connector to the tube.

13. The log making apparatus according to claim 12, wherein the connector unit is configured to elastically deform the connector prior to inserting the connector into the end of the tube.

14. The log making apparatus according to any of claims 1 to 13, wherein the connector unit is configured to clamp the connector onto the end of the tube by plastically deforming at least part of the connector.

15. The log making apparatus according to claim 14, wherein the connector unit is configured to clamp the connector and the hole forming unit is configured to form the holes simultaneously.

16. The log making apparatus according to any of claims 1 to 18, wherein the tube support comprises an extendable tube support section, wherein a longitudinal axis of the extendable tube support section aligns with a longitudinal axis of the tube support, optionally wherein the extendable tube support section is supported by a wheel.

17. The log making apparatus according to any of claims 1 to 15, further comprising a container, wherein the tube support, the hole forming unit and the connector unit are disposed in the container, wherein the container comprises a base, a roof and four walls, wherein optionally, the container is portable; andwherein the tube support comprises an extendable tube support section, wherein a longitudinal axis of the extendable tube support section aligns with a longitudinal axis of the tube support, optionally wherein the extendable tube support section is supported by a wheel.

18. The log making apparatus according to claim 17, wherein a length of the extended tube support is greater than a longitudinal length of the container.

19. The log making apparatus according to any of claims 1 to 16, further comprising a container, wherein the tube support, the hole forming unit and the connector unit are disposed in the container, wherein the container comprises a base, a roof and four walls, wherein optionally, the container is portable.

20. The log making apparatus according to any one of claims 17-19, wherein at least one wall comprises a removeable panel.

21. The log making apparatus according to any one of claims 17-20, wherein the container comprises one or more hooks on an outer surface configured such that the container may be lifted.

22. The log making apparatus according to claims 1 to 21, comprising a plurality of tube supports, which are substantially parallel and configured to support respective tubes.

23. The log making apparatus according to claim 22, wherein each of the plurality of tube supports has a corresponding hole forming unit and connector unit.

24. A system for manufacturing logs comprising:a tube forming unit configured to form a tube from a sheet of metal, and the log making apparatus of any one of claims 1 to 23.

25. A method of manufacturing a log, comprising:holding a tube with a tube support, the tube having a longitudinal axis and ends;forming a pair of holes at a location spaced apart from the ends via a hole forming unit;attaching a connector to an end of tube via a connector unit.

26. The method according to claim 25, wherein the method manufactures the log using the apparatus of any one of claims 1 to 23.

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