Automated Assembler with Sensor-Guided Lumber Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated assembly machines for manufactured housing are limited by high setup times when converting between different subcomponent types, restricting them to batch building and stockpiling, and lack flexibility in handling various lumber configurations.
Innovation Solution
An automated assembler system equipped with sensors, guides, and fastening tools, including machine learning models, to identify and position lumber pieces accurately and efficiently form assembled products, enabling flexible production of multiple types without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated assembly machines are used for manufactured housing, then assembly speed and quality are improved, but setup time increases when converting between different subcomponent types
Solution Approach 1:
The assembly machine employs adjustable and reconfigurable components that can dynamically adapt to different subcomponent types. The system includes adjustable positioning fixtures, reconfigurable guide rails, and programmable control systems that can be quickly modified between production runs, enabling the machine to maintain high assembly speed while minimizing setup time through flexible adaptation rather than fixed configuration
Solution Approach 2:
The system utilizes programmable parameters and configurable settings that can be rapidly changed through software control. The assembly machine stores multiple configuration profiles for different subcomponent types, allowing operators to switch between production modes by loading different parameter sets, thereby reducing setup time while maintaining precise assembly quality across various product types
2Manufacturing precision
If automated assembly machines are used for manufactured housing, then assembly quality is improved, but flexibility in handling various lumber configurations decreases
Solution Approach 1:
The assembly machine is designed with universal fixtures and multi-functional positioning systems that can accommodate various lumber configurations. The system includes adjustable clamps, reconfigurable guide structures, and programmable control that enable the same machine to handle different wood types, sizes, and arrangements while maintaining consistent assembly quality across all configurations
Solution Approach 2:
The system employs dynamic positioning and adjustment mechanisms that can adapt to different lumber configurations in real-time. The adjustable fixtures and reconfigurable guides allow the machine to maintain precise alignment and assembly quality whether working with standard dimensional lumber, engineered wood products, or irregularly shaped components
3Adaptability or versatility
If hand assembly is used for subcomponents, then flexibility is improved, but production speed decreases
Solution Approach 1:
The automated assembly machine incorporates self-adjusting fixtures and automated positioning systems that can independently adapt to different lumber configurations without manual intervention. The system uses sensors and feedback mechanisms to automatically adjust positioning, enabling the machine to maintain the flexibility of hand assembly while achieving the high production speeds of automation
Data Source
AI summary
An automated assembler may include an input feeder and an assembly sub-system configured to receive two or more pieces of input lumber from the input feeder. The assembly sub-system may include one or more sensors to generate sensor data associated with at least one of positions or orientations of the two or more pieces of input lumber, one or more guides configured to position at least some of the two or more pieces of input lumber in a selected orientation based on data from the one or more sensors, and one or more fastening tools configured to fasten the two or more pieces of input lumber to form an assembled product. The automated assembler may further include one or more output feed conveyors configured to receive the assembly sub-system.