Automated Framing Assembly System with Conveyor and Position Sensor
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Solution Overview
Problem
The assembly of framing components in construction is labor-intensive, time-consuming, and prone to inaccuracies, with high labor costs and safety risks due to the complexity of assembling multiple pieces by hand, necessitating a system for faster, more efficient, precise, and safe assembly.
Innovation Solution
A system comprising a conveyor with rollers, a holder, and a fastening tool, controlled by a position sensor and controller, which automatically and repeatably assembles framing components by conveying elements and spacers, temporarily fixing their position, and driving fasteners into predetermined locations, enhancing speed, efficiency, and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If framing components are assembled by hand one by one, then flexibility and adaptability are maintained, but assembly speed and productivity are significantly reduced
Solution Approach 1:
The assembly system is divided into modular components including a conveyor system with rollers, individual positioning mechanisms for each element, separate fastening stations, and independent control units. This segmentation allows the complex assembly task to be broken down into manageable segments that can be automated while maintaining overall system flexibility.
Solution Approach 2:
The automated assembly system is designed with universal components that can handle multiple types of framing elements (studs, joists, rafters, etc.). The conveyor system and positioning mechanisms are configured to accommodate various dimensions and configurations, allowing a single system to perform multiple assembly functions rather than requiring dedicated equipment for each component type.
2Manufacturing precision
If hand assembly is used for complex framing components, then adaptability to different configurations is maintained, but manufacturing precision and repeatability deteriorate
Solution Approach 1:
The system incorporates sensors and control mechanisms that monitor the position and orientation of framing elements during assembly. This feedback allows the automated system to detect and correct positioning deviations, ensuring consistent precision across all assembled components while maintaining the ability to adapt to different configurations through programmable control.
Solution Approach 2:
Framing elements are pre-positioned and pre-aligned on the conveyor system before the actual assembly operation. This preliminary action ensures that elements are correctly oriented and positioned prior to fastening, enabling the automated system to achieve high precision without requiring complex real-time adjustments during the assembly process.
3Loss of time
If manual assembly of multiple framing components is performed, then system simplicity is maintained, but labor costs and time consumption increase
Solution Approach 1:
The conveyor-based assembly system enables continuous movement of framing elements through the assembly process, eliminating idle time between operations. Elements are continuously conveyed, positioned, and fastened in an uninterrupted sequence, maximizing productivity while the modular design keeps equipment complexity manageable through standardized components.
Solution Approach 2:
Multiple assembly operations (conveying, positioning, fastening, and finishing) are merged into a single integrated system that processes multiple framing components simultaneously. This consolidation reduces overall assembly time while the modular architecture maintains reasonable equipment complexity by combining functions rather than requiring separate equipment for each operation.
4Reliability
If hand assembly is used for framing components, then safety risks are reduced through simpler equipment, but worker safety actually deteriorates due to repetitive manual labor and heavy lifting
Solution Approach 1:
The assembly system is designed to handle heavy framing elements and perform forceful fastening operations automatically, eliminating the need for workers to manually lift heavy components or operate dangerous tools. The system serves itself by automatically positioning, aligning, and securing elements, thereby improving safety while the automated mechanisms manage the inherent complexity of handling construction materials.
Data Source
AI summary
A system for assembling elements into framing components is provided along with a method for the use thereof. The system may comprise a frame, a fastening tool, a first conveyor, a second conveyor, and a holder. The pieces of the system may be connected so that they may operate automatically, with only minimal operation by a user. The system increases the speed, efficiency, precision, repeatability, and safety of assembling framing components.