Stationary Vertical Assembly Table for Automated Wooden Construction
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Solution Overview
Problem
Traditional methods for manufacturing wooden constructions using rod-like members, such as roof trusses and wall frames, are labor-intensive and prone to dimensional inaccuracies due to manual handling and complex assembly line systems, leading to increased costs and rejected products.
Innovation Solution
A method and apparatus utilizing a stationary assembly table with vertically mounted grippers that can be magnetically or suction-attached, allowing for fully automated assembly of rod-like members into wooden constructions, with an automatic assembly robot forming joints using nail plates, screws, staples, or adhesives, and a modular assembly table that can be easily expanded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used for assembling rod-like members on a horizontal assembly line, then flexibility in assembly process is maintained, but labor intensity increases and manufacturing precision deteriorates
Solution Approach 1:
The patent inverts the conventional horizontal assembly approach by implementing a vertical assembly table where rod-like members are assembled in a upright position. This inversion allows gravity to assist in positioning and enables automated grippers to efficiently handle members, thereby improving dimensional accuracy while facilitating automation without requiring manual intervention.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated robotic grippers and positioning systems. The vertical assembly table incorporates automated mechanisms that can precisely position and secure rod-like members, eliminating the imprecision and labor intensity associated with manual handling while maintaining operational flexibility.
2Productivity
If a horizontal assembly line with multiple stations is used, then assembly flexibility is maintained, but space requirements increase and manufacturing time increases due to temporary fastening
Solution Approach 1:
The patent merges multiple assembly operations into a single vertical assembly table, eliminating the need for separate horizontal assembly line stations. The integrated system allows simultaneous positioning, joining, and securing of rod-like members without requiring temporary fastening and subsequent removal, thereby reducing manufacturing time and increasing productivity.
Solution Approach 2:
The vertical assembly table enables preliminary positioning and securing of rod-like members in their final positions during the initial assembly phase. This preliminary action eliminates the need for subsequent temporary fastening and repositioning operations, directly reducing manufacturing time and improving efficiency.
3Extent of automation
If a vertical assembly table with movable beams and pillars is used, then automation capability is improved, but device complexity increases and control mechanism difficulty increases
Solution Approach 1:
The patent extracts and eliminates the complex movable beams, pillars, and rail systems from the assembly table design. By adopting a stationary vertical assembly table with fixed mounting positions for grippers, the system maintains automated assembly capability while dramatically reducing device complexity and eliminating the need for complex control mechanisms to coordinate multiple moving parts.
Solution Approach 2:
The patent segments the automated assembly function into fixed, modular gripper units mounted on the stationary assembly table. Each gripper operates independently at its designated position, eliminating the need for coordinated movement of large structural components. This segmentation maintains automation while simplifying the overall system architecture and control requirements.
4Manufacturing precision
If horizontal assembly line with moving truss is used, then assembly automation is achieved, but joint dimension accuracy deteriorates
Solution Approach 1:
The patent inverts the conventional approach by eliminating truss movement entirely and assembling members in a stationary vertical position. This inversion allows precision positioning of each rod-like member relative to its joining points without the dimensional variations introduced by movement, thereby improving joint dimension accuracy while maintaining efficient assembly throughput.
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
This approach significantly reduces labor costs, ensures dimensional accuracy, minimizes rejected products, and allows for efficient production of complex wooden structures with reduced space requirements, enabling flexible expansion and precise control over the manufacturing process.
Implementation Method 1
the grippers are fastened basically to any point on the fastening plane... the fastening plane is manufactured of a ferrous material and the grippers are fastened to the assembly table magnetically
Implementation Method 2
the grippers are fastened to the fastening plane by means of a suction pad gripper located in the grippers
Data Source
AI summary
In the method, grippers (110, 140) are placed on a stationary assembly table (100) and rod-like members forming a wooden construction are laid on the support of said grippers. The wooden construction can be for example a roof truss or a wall frame. The assembly table comprises a vertical fastening plane (104) to which the grippers are fastened. The fastening plane can be made of ferrous material and the grippers can be fastened to the fastening plane magnetically or by means of a suction pad gripper. The fastening of the grippers to the fastening plane, the fastening of the rod-like members to the grippers and the joint connecting the rod-like members are conducted by means of an assembly robot (200). The joint may be a nail plate joint, a nail, screw or staple joint or a glued joint. From the CAD file of the wooden construction a list of commands controlling the operation of the assembly robot is generated by means of a decompression program. The grippers belonging to the apparatus comprise first grippers (110) and second grippers (140). The first grippers comprise a frame to be fastened to the fastening plane and a supporting part fastened to the frame. The supporting part comprises a face supporting surface to be positioned against the face of the rod-like member, an edge supporting surface to be positioned against the edge surface and a pivot plate for pressing the rod-like member against the face supporting surface. The second grippers comprise a frame to be fastened to the fastening plane and a gripping bracket. The gripping bracket comprises a grip surface to be positioned against the face of the rod-like member, a lip to be positioned against the edge surface, as well as a gripping member, such as a suction pad, for adhering to the surface of the rod-like member.