Drop-Down Assembly Table for Truss Ejection Automation
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Solution Overview
Problem
Existing assembly tables for structural members, such as trusses, often lead to repetitive motion injuries for workers and complicate the ejection of assembled members due to the need to elevate them above end datums, which can require larger rollers and slots, hindering automated assembly.
Innovation Solution
A structural member assembly table with a drop-down platform that pivots from a horizontal operational position to a perpendicular eject position, allowing assembled members to be ejected without elevating them above the end datum, and featuring powered conveyor rollers and a gantry for nail plate insertion, facilitating efficient and automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If assembled structural members are elevated above the end datum for ejection, then ejection is enabled, but larger rollers and slots are required, increasing device complexity
Solution Approach 1:
The platform is made dynamically movable between a first position (during assembly) and a second position (during ejection). This dynamic repositioning allows the platform to clear the end datum during ejection without requiring permanent elevation of the structural member, thereby enabling ejection capability while avoiding the need for larger rollers and slots that would be required if the member were permanently elevated.
Solution Approach 2:
Instead of resolving the ejection problem in the vertical dimension (elevating the member above the end datum), the solution moves the obstruction (the platform) in the horizontal dimension by pivoting it to a second position. This dimensional shift allows the structural member to pass over the end datum and onto the conveyance mechanism without requiring vertical elevation, thus avoiding the need for larger rollers and slots.
2Device complexity
If manual assembly methods are used, then device complexity is reduced, but repetitive motion injuries occur and productivity decreases
Solution Approach 1:
The system incorporates automated conveyance mechanisms that automatically transport structural members through the assembly process. The powered conveyance mechanism receives members from the assembly area and transports them without requiring manual handling, allowing the system to serve itself in the material handling aspect and enabling higher productivity through automation.
Solution Approach 2:
Manual mechanical assembly operations are replaced with an automated system comprising a controlled environment, automated conveyance mechanisms, and coordinated assembly operations. This substitution of manual mechanical systems with automated mechanical and control systems increases productivity while managing the complexity through integration.
3Reliability
If manual handling of structural members is used, then equipment cost is reduced, but worker injuries increase
Solution Approach 1:
The automated conveyance mechanism enables the system to handle structural members without human intervention in the material handling aspects. The powered conveyance automatically receives, transports, and positions members, making the system self-sufficient in material handling and eliminating workers from exposure to repetitive motion injuries associated with manual handling.
Solution Approach 2:
The hazardous function of manual material handling is extracted from the assembly system and replaced with automated conveyance mechanisms. By taking out the manual handling operation and replacing it with powered conveyance, the system eliminates the source of repetitive motion injuries while managing the added complexity through dedicated automated handling infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces worker injuries, improves assembly quality, and enhances manufacturing output by enabling efficient ejection and automated handling of assembled structural members, minimizing the need for large rollers and slots, and ensuring consistent assembly heights.
Implementation Method 1
a drop-down mechanism configured to downwardly pivot the support surface relative to the work surface from an operational position to an eject position
Implementation Method 2
a drop-down mechanism configured to downwardly pivot the support surface
Implementation Method 3
The end datum is configured to set a length of the floor truss in cooperation with a fixed end datum and to apply a longitudinal compressive force to the structural member
Implementation Method 4
powered conveyor rollers onto a conveyor portion of the assembly table
Data Source
AI summary
Devices, systems, and methods used to assemble a structural member, such as a floor truss, are disclosed. The systems include a structural member assembly table including a worktable and a drop-down platform pivotably coupled to the worktable. The drop-down platform includes an end datum and a drop-down mechanism coupled to the support surface. The drop-down mechanism is configured to transition the support surface from an operational position to an eject position to drop the end datum below a work surface of the worktable to eject the assembled structural member from the worktable.