Robotic Pre-Plating of Structural Members for Accurate Truss Joints
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Solution Overview
Problem
Current methods for constructing trusses lack efficiency in pre-plating structural members, as they require manual alignment and securing of plates at joints, which is time-consuming and prone to errors.
Innovation Solution
A pre-plating system comprising robots and automated mechanisms that pick, position, and secure plates onto structural members using suction, gripping, and magnetic mechanisms, allowing for precise placement and alignment without indicia, enabling faster and more accurate assembly of trusses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment and securing of plates at joints is used, then the process allows flexibility in handling, but the construction time increases and accuracy decreases
Solution Approach 1:
The system performs preliminary positioning of plates on structural members before final securing. The robotic system places plates in predetermined positions based on digital models, and the pressing operation secures them in advance before actual truss assembly, eliminating the need for time-consuming manual alignment during construction.
Solution Approach 2:
The patent replaces manual mechanical alignment and securing operations with an automated robotic system. The robotic arm with end effector performs plate placement and pressing operations, substituting human labor with automated machinery that operates faster and with greater precision.
2Manufacturing precision
If manual plate placement is used, then the system is simpler, but the accuracy of plate positioning decreases
Solution Approach 1:
The system incorporates vision systems and sensors that capture images of structural members and plates, process this visual information, and use it to guide the robotic arm for precise plate placement. The feedback loop ensures accurate positioning by continuously monitoring and adjusting the robotic system's actions based on real-time data.
Solution Approach 2:
The robotic system with interchangeable end effectors serves multiple functions: picking up plates, positioning them accurately, and pressing them onto structural members. This multi-functional approach achieves high precision without requiring separate specialized devices for each operation, thereby managing system complexity.
3Productivity
If automated robotic systems are used, then construction time is reduced, but the initial system complexity increases
Solution Approach 1:
The automated system is divided into distinct functional modules: a robotic arm for movement, an end effector for plate handling, a pressing mechanism for securing plates, and a control system for coordination. This segmentation allows each component to be optimized independently and simplifies maintenance and operation while achieving high productivity.
Solution Approach 2:
The patent combines multiple functions into an integrated robotic system where the robotic arm, end effector, and pressing mechanism work as a unified automated assembly system. This merging of functions into a coordinated system achieves high truss assembly efficiency by eliminating the need for separate manual operations for each step.
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 significantly reduces construction time and improves accuracy by automating the pre-plating process, enhancing the efficiency and reliability of truss assembly by using robots to handle and secure plates onto structural members with precision.
Implementation Method 1
picking, positioning, and securing plates onto structural members using suction, gripping, and magnetic mechanisms
Implementation Method 2
picking, positioning, and securing plates onto structural members using suction, gripping, and 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.