Continuous Floor Assembly Line With Automated Conveyance and Gang Nailing
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Solution Overview
Problem
Current manufactured building construction processes rely heavily on human labor for assembling the floor, which are time-consuming, ergonomically disadvantageous, and limited by the physical capabilities of personnel, leading to production constraints.
Innovation Solution
An automated system for assembling the floor of a manufactured building using automated conveyance systems, gang nailing, and automated part location marking, controlled by a programmable logic controller, which includes a perimeter rail transport system, gang nailing system, printer system, floor joist board transport system, and floor joist board attachment operator station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated conveyance systems and gang nailing are used, then productivity increases, but device complexity increases
Solution Approach 1:
The assembly system is divided into distinct functional modules: perimeter rail transport system, gang nailing system, printer system, floor joist board transport system, and operator stations. Each module performs a specific function and can operate semi-independently, allowing the system to handle complex assembly tasks through coordinated simple units rather than a single complex unit.
Solution Approach 2:
A programmable logic controller (PLC) serves as the intermediary that coordinates all automated systems. The PLC receives floor plans, processes them into assembly instructions, and controls the timing and operation of conveyance systems, gang nailers, and printers, enabling complex coordinated action through a centralized control intelligence rather than complex mechanical coordination.
2Manufacturing precision
If automated gang nailing is used, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The gang nailing system incorporates sensors that detect the position of rim joist boards and the timing of nail placement. The system uses feedback from these sensors to adjust the nailing operation in real-time, ensuring precise nail placement at correct intervals and positions, thereby achieving high manufacturing precision through controlled feedback loops rather than complex mechanical positioning mechanisms.
3Productivity
If continuous assembly process is implemented, then productivity increases, but loss of time in setup and transition increases
Solution Approach 1:
Floor plans are pre-loaded into the programmable logic controller before the continuous assembly begins. The system pre-processes assembly instructions, material requirements, and timing sequences in advance. This preliminary preparation allows the system to start continuous assembly immediately without time-consuming on-site setup, as all control parameters and material flow sequences are already predetermined and optimized.
Data Source
AI summary
A system is described that assembles a floor for a manufactured building in a continuous fashion. Unlike current methods in which framing and decking members are carried manually along a jig or table to the point of installation, the system includes an automated conveyance apparatus that moves material through various stations where floor components are assembled at a continuous preprogrammed rate. Key aspects of the system include continuous assembly, automated material conveyance, automated gang nailing, and automated part location marking.