Automated Floor and Ceiling Framing Assembly With In-Line Quality Control
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Solution Overview
Problem
Existing modular building assembly systems suffer from inflexibility, requiring manual intervention, limited material and fastener types, and lack of quality control, leading to inefficiencies and increased costs.
Innovation Solution
A system and method for assembling framing assemblies in modular construction units, utilizing a truss storage area, truss elevator, joist placement system, framing system, sheathing/drywall installation, and fastening system to automate the assembly process, allowing for flexible use of materials and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated systems are used for assembling framing assemblies, then productivity and precision are improved, but device complexity increases
Solution Approach 1:
The automated assembly system is divided into distinct functional modules: a framing assembly module that receives and positions trusses and joists, a fastening module that applies fasteners, and a sheathing module that installs panel members. Each module operates independently but coordinates through the conveyor system, allowing the complex automation task to be managed through modular components rather than a monolithic system.
Solution Approach 2:
The conveyor system serves multiple functions: it transports framing assemblies between modules, positions components for assembly, and coordinates the movement of multiple modules simultaneously. This multi-functional conveyor acts as a universal platform that enables the entire automated assembly process without requiring separate specialized equipment for each operation.
2Adaptability or versatility
If multiple material types and fastener configurations are supported, then adaptability is improved, but device complexity increases
Solution Approach 1:
The fastening module employs adjustable fastening devices that can dynamically change their configuration and parameters. The devices can accommodate different fastener types, patterns, and spacing requirements by adjusting their positioning and operational parameters, allowing the system to adapt to various material combinations without requiring completely different tooling for each scenario.
Solution Approach 2:
The system achieves versatility by changing operational parameters rather than physical hardware. The fastening module can modify fastener pattern parameters, spacing parameters, and application parameters to suit different framing configurations. Similarly, the sheathing module can adjust panel placement parameters to accommodate different panel types and sizes, maintaining device simplicity while achieving high adaptability.
3Manufacturing precision
If quality control checks are implemented, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The quality control process is integrated continuously into the assembly flow rather than being implemented as separate inspection stages. Sensors and detection systems operate continuously alongside the assembly modules, monitoring component positioning, fastener application, and panel installation in real-time as items move along the conveyor. This eliminates idle inspection time and maintains continuous production throughput while ensuring quality standards are met.
Solution Approach 2:
The system incorporates feedback mechanisms where quality control sensors detect deviations from specifications and immediately communicate this information to the assembly modules. The feedback loop enables real-time adjustments to be made during the assembly process itself, correcting issues before they become defects and eliminating the need for separate rework stages that would reduce productivity.
Data Source
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AI summary
A system and method for assembling framing assemblies for use as ceiling or floor structures of modular building units using automation are disclosed. The framing assemblies include trusses that are attached at the lateral edges thereof by a joist including at least one layer of dimensional lumber to form a substantially rigid framework. Cover panels are positioned over and attached to an inner surface of the framing assembly.