Automated Truss Assembly with Pre-Plated Members
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Solution Overview
Problem
The truss manufacturing process is highly customized, leading to inefficiencies and errors in manual assembly, despite advancements in automation, as the placement of lumber and connectors remains largely manual, especially for the bottom face of truss members which is not easily accessible.
Innovation Solution
A truss assembly system that automates the sequential placement of pre-plated truss members using a modular system with stations for cutting, pre-plating, transport, and assembly, employing robots and conveyors to streamline the process, allowing for automatic alignment and assembly based on pre-defined truss designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly methods are used for truss fabrication, then flexibility in handling customized designs is maintained, but assembly efficiency and precision deteriorate due to manual errors and time-consuming processes
Solution Approach 1:
The automation system is divided into distinct functional modules: a cutting station for processing lumber, a pre-plating station for attaching connectors, a transport station for moving members, and an assembly station for final truss construction. Each module operates independently but coordinates through the control system, allowing the complex automation task to be managed through modular components that can be individually optimized and maintained.
Solution Approach 2:
The pre-plating station performs connector attachment on lumber members before they reach the assembly station. This preliminary action ensures that connectors are precisely positioned and secured in advance, eliminating the need for manual connector placement during final assembly and reducing assembly time while maintaining high precision through automated positioning systems.
2Manufacturing precision
If automated cutting and pre-plating stations are implemented, then manufacturing precision and consistency improve, but setup time and initial complexity increase
Solution Approach 1:
The control system serves multiple functions: it manages the cutting station for precise lumber dimensional control, operates the pre-plating station for accurate connector positioning, coordinates the transport station, and directs the assembly station. This universal control architecture allows a single system to handle various truss designs and configurations, reducing the need for separate specialized systems and minimizing setup time through programmable reconfiguration.
3Extent of automation
If the bottom face of lumber members is made accessible for connector placement, then complete automation becomes possible, but the complexity of the assembly process increases due to additional lifting and positioning requirements
Solution Approach 1:
The assembly station utilizes vertical space by positioning the assembly surface above the lumber storage area. Lumber members are transported horizontally on the transport station, then vertically elevated to the assembly station where the robotic arm can access both top and bottom faces. This dimensional transition from horizontal to vertical arrangement enables complete automation without requiring complex lateral lifting mechanisms.
Data Source
AI summary
A truss assembly system may include a truss assembly station. The truss assembly station may be configured to enable assembly of a truss from truss members via 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.