Removable Plank Truss Jig with Laser Projection
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Solution Overview
Problem
The complexity and variation in modern truss designs lead to increased production time and operator error in truss assembly, as existing automated systems are either slow, unreliable, or require significant capital investment to replace manual equipment, and are not easily modifiable to accommodate different truss configurations.
Innovation Solution
The introduction of a removable plank unit with a drive motor and puck assembly that allows for translational movement along the plank, enabling flexible puck positioning and easy integration into existing truss assembly tables, combined with a computer control system for automated puck placement, enhancing the efficiency and accuracy of truss assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated puck moving systems are used, then production speed increases, but reliability decreases due to sawdust and debris interfering with puck movement
Solution Approach 1:
The patent replaces the automated mechanical puck moving system with a manual positioning system using laser projection. The laser projects the truss design onto the table surface, allowing operators to manually position pucks accurately without mechanical automation that is susceptible to debris interference.
Solution Approach 2:
The patent uses laser projection to create an optical copy of the truss design on the table surface. This projected image serves as a template that guides manual puck placement, eliminating the need for physical mechanical guides that can be blocked by sawdust and debris.
2Measurement precision
If laser projection systems are used, then measurement accuracy improves, but production time increases due to manual puck positioning
Solution Approach 1:
The patent combines laser projection with manual positioning to achieve accurate puck placement. The laser provides precise visual guidance while manual operation allows for efficient puck movement without the time delays associated with mechanical automation.
3Productivity
If automated truss assembly tables are introduced, then production efficiency increases, but capital expenditure increases significantly
Solution Approach 1:
The patent makes the jigging table universally applicable to different truss designs through laser projection technology. The same table can be reconfigured for various truss types by simply changing the projected design, eliminating the need for multiple specialized tables or expensive automated reconfiguration systems.
Solution Approach 2:
The laser projection system allows digital design files to be copied and projected onto the table surface, enabling rapid reconfiguration for different truss designs without physical modifications to the table itself.
4Device complexity
If manual puck positioning is used, then system complexity remains low, but production time increases and operator error increases
Solution Approach 1:
The laser projection creates a visual copy of the truss design that guides manual puck positioning. This reduces operator error and speeds up the positioning process while maintaining the simplicity of manual operation without complex automated systems.
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
This solution allows for the efficient conversion of manual truss assembly tables into automated systems, reducing production time, minimizing operator error, and providing flexibility in accommodating various truss designs without the need for new equipment, thereby increasing production speed and reducing capital expenditures.
Implementation Method 1
a drive motor secured to the plank. The drive motor has a rotating output member
Data Source
AI summary
The invention as depicted in a preferred embodiment is a retrofitted automated truss assembly jig setting system and one or more removable plank units used therewith. Removable plank unit includes a pair of drive motors each connected to a motor plate that is fixed to the bottom surface of a plank. A pair of rods extends along the length of the plank and each is operatively connected to a motor such that activation of a motor rotates a rod. Puck assemblies are carried by rods and are linearly transposed along rods when motors are activated. A computerized control system is operatively connected to provide for automated positioning of pucks. Planks on existing truss assembly tables may be removed and replaced with removable plank units to turn a traditional truss assembly jigging table into an automated truss assembly jigging table.