Automated Truss Assembly Jig with Vision-Guided Puck Placement
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Solution Overview
Problem
The existing truss assembly systems face inefficiencies and errors due to the manual repositioning of pucks on jigging tables, which increases production time and likelihood of operator error, especially with complex truss designs, and often require significant initial investments to replace manual equipment with automated systems.
Innovation Solution
An automated truss assembly system that uses removable plank units with puck assemblies mounted for translational movement, controlled by a software system that optimizes puck placement on a truss assembly table based on the geometry of the truss, ensuring optimal support and minimizing gaps between pucks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual repositioning of pucks is used on jigging tables, then operator control and flexibility are maintained, but production time increases and operator error likelihood increases
Solution Approach 1:
The system uses vision guidance to automatically detect puck positions and guide the operator's placement actions, making the system self-correcting rather than relying solely on manual measurement accuracy. The vision system provides real-time feedback that enables the operator to self-correct positioning errors.
Solution Approach 2:
The patent replaces manual measurement and positioning mechanisms with an automated vision-based measurement system that uses cameras and image processing to detect puck positions and calculate optimal placement locations, eliminating the need for manual rulers and measurement tools.
2Productivity
If automated puck moving systems are implemented, then speed and efficiency increase, but reliability and consistency issues arise due to debris in slots
Solution Approach 1:
The vision system continuously monitors puck positions and automatically detects any deviations or misalignments, enabling the system to self-correct positioning errors without mechanical intervention. This eliminates the reliability issues associated with mechanical systems that can be blocked by debris.
Solution Approach 2:
The patent replaces mechanical automated puck moving systems with a vision-guided manual positioning system. Instead of using motors and mechanical actuators that can be blocked by sawdust and debris, the system uses optical fields and image processing to guide the operator in placing pucks accurately, eliminating mechanical failure modes.
3Productivity
If complete replacement of manual equipment with automated systems is done, then productivity increases, but significant initial investment is required
Solution Approach 1:
The patent extracts only the essential function of automation (position calculation and guidance) and implements it through software and vision systems, while leaving the physical puck handling to remain manual. This selective automation approach provides productivity benefits without requiring complete mechanical system replacement.
Solution Approach 2:
The vision system serves multiple functions: it guides puck placement, verifies puck positions, detects truss member locations, and provides feedback for quality control. This multi-functionality is achieved through software rather than multiple separate mechanical systems, reducing overall system cost while maintaining productivity benefits.
Data Source
AI summary
A method of automatically placing pucks on a truss assembly table includes the steps of receiving input regarding the truss assembly table and a truss to be assembled on the truss assembly table, and processing the input. Locations on the truss assembly table for each puck are selected based on the processed input that optimizes the overall support given to the truss. The pucks are automatically moved to their selected locations.