Robotic Pre-Plating of Structural Members for Accurate Plate Alignment
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Solution Overview
Problem
Current methods for pre-fabricating building structures, such as trusses, face inefficiencies in splicing and pre-plating structural members, particularly in accurately positioning and securing plates to form joints and longer structural members, which can lead to errors and increased construction time.
Innovation Solution
A pre-plating system that includes a plate picking robot, transfer pedestal, press loading robot, infeed and outfeed robots, and intelligent conveyor systems to accurately position and secure plates onto structural members, enabling efficient splicing and pre-plating of joints and longer structural members by using robots and conveyor systems to handle and align components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used for positioning and securing plates to structural members, then device complexity is reduced, but manufacturing precision and productivity deteriorate
Solution Approach 1:
The system uses vision systems to automatically detect and locate structural members and plates, eliminating the need for manual positioning measurements. The robotic end effectors self-adjust to align plates precisely with structural members through automated feedback control, achieving high positioning accuracy without complex manual intervention systems.
Solution Approach 2:
Manual mechanical positioning methods are replaced with automated robotic systems equipped with vision guidance. The robotic end effectors use sensors and control systems to automatically position and secure plates, replacing manual measurement and alignment tools while improving precision and reducing overall system complexity through integration.
2Productivity
If automated robotic systems are used for plating structural members, then productivity is improved, but device complexity increases
Solution Approach 1:
The system merges multiple functions into integrated robotic end effectors that combine plate handling, positioning, and securing operations in a single automated unit. The conveyor system is integrated with robotic manipulators and vision systems to create a unified automated production line, improving productivity while managing complexity through functional integration.
Solution Approach 2:
The robotic end effectors are designed with universal capabilities to handle different types of plates and structural members through programmable control. The system can perform multiple operations including picking, positioning, and securing various plate configurations, enabling high productivity across diverse applications without requiring separate specialized systems for each task.
3Manufacturing precision
If automated positioning systems are used, then manufacturing precision is improved, but loss of time in setup and alignment increases
Solution Approach 1:
The vision system performs preliminary detection and localization of structural members and plates before the robotic picking operation begins. The system pre-calculates positioning parameters and aligns coordinate systems in advance, enabling the robotic end effector to execute precise placement without time-consuming alignment adjustments during the actual picking and securing process.
Data Source
AI summary
Plating systems and related methods are disclosed for prepping of structural members, such as splicing and/or pre-plating structural members. A plating system can include a splicing system and a pre-plating system. A splicing system include an infeed system, an outfeed system, and a press to affix or otherwise secure a plate to opposing surfaces of structural members to splice the structural members together. Guides are automatically positioned to guide short members through the splicing system. A pre-plating system includes a press, an infeed system configured to deliver a structural member to the press, and an outfeed system configured to remove the structural member from the press. The press is configured to secure a plate to the structural member on a surface other than the opposing surfaces used to splice the structural members together. A plate picking robot is configured to pick a plate from a plate container and position the plate on a press surface.