Automated Wall Panel Assembly with Movable Carriage
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Solution Overview
Problem
The construction of wall panels with rough openings is limited by the need for manual customization and variation in size and placement, which increases setup and change-over time and hinders automation, especially when constructing panels of different heights and extended lengths.
Innovation Solution
A system comprising a horizontal table with a stationary section and a movable carriage, an articulating arm unit with a gripper, and clamping units, controlled by a controller, allows for the automated construction of wall panels of varying lengths by programmatically determining the dimensions and sequence of structural members and their placement, enabling the creation of panels with rough openings and accommodating inconsistent member dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual customization is used to construct wall panels with rough openings, then adaptability to different designs is improved, but productivity decreases due to increased setup and change-over time
Solution Approach 1:
The system employs a movable carriage that can dynamically reposition along the table to accommodate different panel configurations. The carriage moves to different positions based on the specific rough opening requirements, enabling the system to adapt to various designs while maintaining automated construction and high productivity.
Solution Approach 2:
The system changes operational parameters such as carriage position, clamping unit positioning, and articulating arm trajectories based on the specific panel design requirements. By programmatically adjusting these parameters, the system achieves adaptability to different rough opening configurations without manual reconfiguration, thus maintaining high productivity across varying designs.
2Productivity
If automated construction is implemented, then productivity is improved, but device complexity increases due to the need for movable carriage and coordinated clamping units
Solution Approach 1:
The movable carriage serves multiple functions: it positions clamping units, supports structural members during assembly, and coordinates with the articulating arm unit. This multi-functionality reduces the need for separate dedicated mechanisms, thereby managing device complexity while achieving automated construction and high productivity.
Solution Approach 2:
The system merges the clamping units with the movable carriage, combining positioning and clamping functions into a single integrated mechanism. This consolidation reduces the number of independent components and simplifies the overall system architecture, making automated construction more manageable despite the added complexity of automation.
3Adaptability or versatility
If extended length panels are constructed, then adaptability to different panel sizes is improved, but the ability to maintain precision increases difficulty due to the movable carriage
Solution Approach 1:
The controller receives feedback on the carriage position and coordinates clamping unit movements accordingly. This closed-loop control ensures that even as the carriage moves to accommodate extended length panels, the clamping units maintain precise positioning and coordination with the articulating arm unit, preserving manufacturing precision across different panel sizes.
Solution Approach 2:
The controller acts as an intermediary that coordinates the movements of the movable carriage, clamping units, and articulating arm unit. By centrally managing the interactions between these components, the controller ensures that precision is maintained even when constructing panels of extended lengths or varying sizes.
Data Source
AI summary
A system for constructing wall panels comprising a plurality of structural members includes: a source of structural members of predetermined size; a horizontal table configured to support planks as they are being formed into a wall panel, the table including a stationary section and a movable carriage that is configured to move in a longitudinal direction toward and away from the stationary section; an articulated arm unit having a gripper, the articulating arm unit positioned to retrieve boards from the source with the gripper and place them on the table; at least one first clamping unit mounted to the stationary section for clamping structural members thereto; at least one second clamping unit mounted to the movable carriage for clamping structural members thereto; and a controller that controls the movement of the articulating arm unit and the movable carriage.