Robotic Pre-Plating of Structural Members Without Alignment Indicia
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Solution Overview
Problem
Current methods for pre-fabricating structural members, such as trusses, are inefficient in securely coupling plates to structural members without relying on indicia or precise positioning, leading to potential misalignment and reduced structural integrity.
Innovation Solution
A pre-plating system comprising robots and a press that automatically picks, positions, and secures plates to structural members using suction, gripping, or magnetic mechanisms, with the ability to determine the centroid of the structural member for precise alignment and secure plate attachment, enabling efficient and accurate pre-plating of structural components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual methods are used to couple plates to structural members, then flexibility and adaptability are maintained, but manufacturing precision and productivity are reduced
Solution Approach 1:
The system determines the centroid of the structural member automatically and uses this information to position the plate precisely without requiring external indicia or complex positioning fixtures. The robotic system serves itself by using the structural member's own geometric properties for alignment
Solution Approach 2:
Manual mechanical positioning and alignment operations are replaced with an automated robotic system that uses sensor-based centroid detection and controlled motion to achieve precise plate placement, eliminating the need for manual measurement and alignment tools
2Manufacturing precision
If manual positioning methods are used without indicia, then ease of operation is maintained, but manufacturing precision deteriorates
Solution Approach 1:
The centroid determination serves as an intermediary measurement that bridges the gap between the structural member's geometry and the plate positioning requirement. By calculating the centroid from the member's shape and mass distribution, the system obtains precise positioning information without requiring physical markers or indicia on the structural member
3Productivity
If automated robotic systems are implemented, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The robotic system is designed to perform multiple functions: it positions structural members, determines centroids, positions plates, and couples plates to members. This multi-functionality reduces the need for separate specialized equipment for each operation, thereby managing device complexity while maintaining high productivity
Solution Approach 2:
The system determines the centroid of the structural member before plate placement, performing preliminary positioning calculations and adjustments. This preliminary action enables the robotic system to execute the plate coupling operation efficiently in a single motion, increasing productivity without requiring complex real-time adjustment mechanisms
4Reliability
If traditional coupling methods are used, then device complexity is minimized, but structural integrity and reliability are reduced
Solution Approach 1:
The robotic system uses pneumatic or hydraulic actuators to apply controlled force during plate coupling, ensuring consistent and reliable plate-to-member connection. This automated force application improves structural integrity by eliminating variability in manual coupling force while managing system complexity through integrated actuation
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 system enhances the efficiency and accuracy of pre-plating structural members, ensuring secure coupling of plates to structural members without the need for indicia, thereby improving the structural integrity and speed of construction processes.
Implementation Method 1
A pre-plating system comprising robots and a press that automatically picks, positions, and secures plates to structural members using suction, gripping, or magnetic mechanisms
Implementation Method 2
A pre-plating system comprising robots and a press that automatically picks, positions, and secures plates to structural members using suction, gripping, or magnetic mechanisms
Data Source
AI summary
Pre-plating systems and related methods are disclosed. A pre-plating system includes a press, an infeed robot configured to deliver a structural member to the press, and an outfeed robot configured to remove the structural member from the press. The press is configured to secure a plate to the structural member while the structural member is held in position by at least one of the infeed robot or the outfeed robot. A pre-plating system includes a press, a transfer pedestal, a plate picking robot, and a press loading robot. The plate picking robot is configured to pick a plate from a container and position the plate on the transfer pedestal. The press loading robot is configured to transfer the plate to the press. The press is configured to press the plate into a structural member positioned within the press.