Automated Truss Assembler with Pre-Plated Members
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Solution Overview
Problem
The truss assembly process in construction is often manual and inefficient due to the custom nature of truss designs, leading to potential errors and increased costs, despite existing automation efforts that focus mainly on cutting and setup functions.
Innovation Solution
A truss assembly system with modular elements and a truss assembler that automatically places pre-plated truss members to form joints, utilizing a computer program product for sequential placement based on pre-defined truss design data, enabling full or partial automation of the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual truss assembly is used, then flexibility in handling custom designs is maintained, but productivity and manufacturing precision deteriorate
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated robotic system that uses computer vision and programmable motion control. The robotic arm with specialized end effectors automates connector placement and member assembly, eliminating manual labor while maintaining the ability to handle custom designs through software programming.
Solution Approach 2:
The system incorporates automated features recognition and self-positioning capabilities where the robotic system automatically identifies truss member positions and orientations using vision systems, then autonomously performs assembly operations without continuous human intervention or manual positioning.
2Device complexity
If manual truss assembly is used, then equipment complexity is reduced, but manufacturing precision and error rates worsen
Solution Approach 1:
The patent replaces imprecise manual operations with an automated robotic system equipped with computer vision, sensors, and programmable control. This substitution enables precise connector placement and member alignment through automated positioning systems, significantly improving manufacturing precision despite the increased device complexity.
Solution Approach 2:
The system incorporates vision systems and sensors that continuously monitor and provide feedback on member positions, connector placement accuracy, and assembly progress. This real-time feedback enables automated correction and verification, ensuring high precision in connector placement and overall assembly quality.
3Productivity
If automated assembly is implemented, then productivity and precision improve, but device complexity increases
Solution Approach 1:
The patent divides the automated assembly system into modular functional units including vision systems, robotic manipulation stations, connector application devices, and control systems. This segmentation allows for targeted automation of specific assembly tasks, improving productivity while managing overall system complexity through modular architecture.
Solution Approach 2:
The robotic system is designed with multi-functional capabilities to perform various assembly operations including member positioning, connector application, and quality inspection. This universality consolidates multiple functions into a single integrated system, improving productivity without proportionally increasing complexity.
4Ease of operation
If connectors are placed manually on bottom faces, then ease of operation is maintained, but productivity and reliability deteriorate
Solution Approach 1:
The patent inverts the traditional approach by having connectors pre-installed on truss members before assembly, rather than placing them during assembly. This inversion allows automated robotic systems to simply position members rather than perform complex connector placement operations, significantly improving productivity while maintaining operational simplicity through standardized member interfaces.
Solution Approach 2:
The system performs preliminary connector installation on individual truss members before they are assembled into the complete truss structure. This preliminary action simplifies the main assembly operation to mere member positioning and connection, thereby increasing assembly speed and reliability while reducing the complexity of real-time connector placement.
Data Source
AI summary
A truss assembly station may include a truss assembler. The truss assembler may be configured to enable assembly of a truss from truss members by providing an automatic sequential placement of the truss members based at least in part upon a planned location of pre-plated truss members within an assembled truss. The pre-plated truss members may be truss members including at least one connector plate installed thereon prior to placement at the truss assembly station.