U.S. patent application number 10/970980 was filed with the patent office on 2005-08-25 for modular housing system.
Invention is credited to Wall, Harlin.
Application Number | 20050186062 10/970980 |
Document ID | / |
Family ID | 34864409 |
Filed Date | 2005-08-25 |
United States Patent
Application |
20050186062 |
Kind Code |
A1 |
Wall, Harlin |
August 25, 2005 |
Modular housing system
Abstract
A modular production system and method for producing wall panels
of a modular building. The system includes a worktable, a plurality
of telescoping tools mounted over the worktable, an overhead tram
disposed adjacent the worktable, and a plurality of material supply
bridges movably supported on the overhead tram so as to be movable
over the worktable. The method of manufacturing a panel of a
modular structure includes moving the first material supply bridge
over a worktable to place panels of sheeting on the worktable, and
then moving a second material supply bridge over the worktable to
place steel members for the construction of a steel frame. A third
material supply bridge is then moved over the worktable to apply
adhesive on the sheeting in a pattern mirroring the steel
frame.
Inventors: |
Wall, Harlin; (State
College, PA) |
Correspondence
Address: |
WENDEROTH, LIND & PONACK, L.L.P.
2033 K STREET N. W.
SUITE 800
WASHINGTON
DC
20006-1021
US
|
Family ID: |
34864409 |
Appl. No.: |
10/970980 |
Filed: |
October 25, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60513222 |
Oct 23, 2003 |
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Current U.S.
Class: |
414/787 |
Current CPC
Class: |
E04B 2001/3577 20130101;
E04B 7/24 20130101 |
Class at
Publication: |
414/787 |
International
Class: |
E04H 005/00; E04H
001/00 |
Claims
I claim:
1. A modular production system for producing wall panels of a
modular building, the system comprising: a worktable; a plurality
of telescoping tools mounted over the worktable; an overhead tram
disposed adjacent the worktable; and a plurality of material supply
bridges movably supported on the overhead tram so as to be movable
over the worktable in a longitudinal direction thereof.
2. The modular production system as claimed in claim 1, further
comprising a controller for controlling operation of the worktable
and the material supply bridges.
3. The modular production system as claimed in claim 2, wherein the
controller comprises a computer.
4. The modular production system as claimed in claim 1, further
comprising a module assembly table for receiving, storing and
assembling wall panels produced at the worktable.
5. The modular production system as claimed in claim 1, wherein the
worktable includes longitudinal encoder tracks supported on a
plurality of telescoping pylon tubes for setting the vertical
position of the longitudinal encoder tracks.
6. The modular production system as claimed in claim 5, wherein the
pylon tubes are movable horizontally toward and away from a central
axis of the worktable.
7. The modular production system as claimed in claim 5, wherein
each of the longitudinal encoder tracks includes at one encoder
actuator head.
8. The modular production system as claimed in claim 1, wherein
each of the plurality of material supply bridges is independently
movable in the longitudinal direction of the worktable, and the
material supply bridges are arranged so that they can cross over or
under each other while performing independent production
procedures.
9. The modular production system as claimed in claim 1, wherein the
plurality of material supply bridges comprises a first supply
bridge for supplying sheeting material to the worktable, a second
supply bridge for supplying steel members to the worktable, and a
third supply bridge for supplying adhesive and insulation to the
worktable.
10. The modular production system as claimed in claim 9, wherein
the first material supply bridge includes opposing sloping pallets
for supporting panel sheets, and a sheet placement device for
moving the sheets from the first material supply bridge to the
worktable.
11. The modular production system as claimed in claim 9, wherein
the second material supply bridge includes welders, metal press
joining equipment, and screw driving devices.
12. The modular production system as claimed in claim 1, wherein
the third material supply bridge includes an adhesive dispensing
device and an insulation spray device.
13. The modular production system as claimed in claim 1, wherein
each of the plurality of telescoping tools comprises two structural
members having interlocked bearing surfaces to permit the tool to
contract and expand in length to accommodate different panel
widths.
14. The modular production system as claimed in claim 1, wherein
the plurality of telescoping tools comprises a transverse
telescoping linear encoded router, a transverse telescoping encoded
material locator, a telescoping linear encoded diamond saw, and a
transverse telescoping linear encoded nailer.
15. The modular production system as claimed in claim 14, wherein
the ends of the telescoping linear encoded diamond saw can be
skewed to enable the saw to make cuts at an angle to the
longitudinal axis of the worktable.
16. The modular production system as claimed in claim 5, wherein
each of the plurality of telescoping tools comprises encoder
actuator heads supported on the longitudinal encoder tracks.
17. A method of manufacturing a panel of a modular structure, the
method comprising: moving a first material supply bridge over a
worktable in a longitudinal direction of the worktable to place
panels of sheeting on the worktable, wherein the first material
supply bridge is supported on an overhead power tram; and moving a
second material supply bridge over the worktable in the
longitudinal direction of the worktable to place steel members for
the construction of a steel frame, wherein the second material
bridge is supported on the overhead power tram.
18. The method of manufacturing a panel of a modular structure as
claimed in claim 17, further comprising connecting the steel
members to form edge beams and intermediate beams of the steel
frame.
19. The method of manufacturing a panel of a modular structure as
claimed in claim 18, further comprising moving a third material
supply bridge over the worktable in a longitudinal direction of the
worktable to apply adhesive on the sheeting in a pattern mirroring
the steel frame, wherein the third material bridge is supported on
the overhead power tram.
20. The method of manufacturing a panel of a modular structure as
claimed in claim 19, further comprising lowering the steel frame so
as to embed the steel frame in the adhesive on the surface of the
sheeting.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/513,222, filed Oct. 23, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a novel system for
constructing modular housing structures. In particular, the modular
housing system produces light gauge steel modular structures. The
system is capable of producing all types of panels including
insulated closed panels having installed electrical and mechanical
system.
[0004] 2. Description of Related Art
[0005] The present inventor, with the benefit of 40 years in the
design and construction industry, has developed a modular housing
system that will provide stronger homes. The system gives full
consideration to national building codes, and the underlying
principles of safety, comfort, energy savings, and green
construction. The housing system will provide the best retirement
plan for America's aging population, a higher quality manufactured
home providing the realization of long term homeowner equity.
[0006] The construction of modular building structures, which are
fabricated at a housing plant, is limited by applicable laws and
regulations. The United States housing industry, which includes
HUD-code homes and modular housing, is controlled by laws that
limit the dimensions of products that can be shipped over the
interstate highways. These limitations include width restrictions
to insure vehicular safety, height restrictions to clear overhead
obstructions, and length restrictions of the modular unit and
transporter.
[0007] Typically manufactured HUD homes and modular homes include
three dimensional "boxes or modules" that are shipped over the
road, and thus are confronted with the continuing problem of the
regulatory shipping limitations. Accordingly, the most economical
roof designs have generally been limited to low and medium pitched
roofs. Also, the height limitations impose constraints on the
design of the building structures, and the building structures have
taken on the connotations associated with the homes produced by the
earlier mobile home industry. Various solutions have been proposed,
such as entirely independent roof sections and saddle roofs that
hang over the side of the module. However, shipping independent
roof sections substantially increases the construction and
transportation costs, and saddle roof designs consume a portion of
the over-the-road regulatory width, thereby reducing the allocable
width of the module living space. Both of these methods have
limitations and increase the cost of equivalent floor area in the
building structures. Furthermore, the applicable laws have created
several limitations within the modular housing industry such
as:
[0008] 1. The dimensional geometry of the shipped product is
restricted to widths of 12 feet, 14 feet, and 16 feet (under
controlled conditions); heights of 14 feet, which includes either
the transporter or wheel and rail assemblies; and lengths of 80
feet.
[0009] 2. The traffic flow patterns within the housing plans are
restricted, which causes stairways to the second floor of 12 foot
and 14 foot wide modules to be L-shaped with landings and returns.
This is necessary to fit the stair within the restricted module
widths, which must ultimately terminate near the center of the
second floor traffic pattern.
[0010] 3. The lengths of the modules are required to be extended,
in the only dimension available, in order to overcome the
limitations of the width of the module. This is necessary to
encapsulate more floor area. Also, as the lengths of the modules
have been extended upward in excess of 70 feet, the modules have
been exposed to increased flexure during shipping and handling,
resulting in increased damage to both the structure and interior
finishes of the module.
[0011] 4. The extended module lengths have created awkward planning
constraints that require the main front entrances of the homes to
be located near the center of the modules in order to minimize the
length of hallways and to improve efficient access to rooms at the
ends of the modules.
[0012] 5. The extended module lengths have necessitated that the
slope direction of the major roof be 90 degrees with respect to the
length of the module in order to remain below the shipping height
limitations. By employing multiple roof panels, which are folded
during shipping and unfolded and tilted up during the erection
process, the housing industry has successfully created techniques
that achieve up to 12/12 roof pitches. However, this requires the
production of additional multiple panels and substantially
increases costs. Furthermore, this process exposes the module to
potential weather damage during the erection procedure.
[0013] 6. The total width of one and two story homes is limited to
two modules having a combined width of approximately 28 feet. This
is necessary in order to avoid the creation of saw-tooth roof
configurations, which are created by joining more than two modules.
Saw-tooth roof configurations are inconsistent with the aesthetics
of traditional home designs. Furthermore, limiting the house width
to two module widths, avoids the complicated water drainage
problems created by the long valleys of saw-tooth roofs. Some patio
homes have been produced in contemporary plans by sliding and
offsetting the modules in a direction parallel to their
longitudinal dimension, thereby reducing the problems associated
with the saw-tooth roofs. However, this has been accomplished by
increasing the exterior wall area, which inherently increases the
heating and cooling costs.
[0014] The above-discussed limitations have affected not only the
housing product itself, but have also imposed restrictions on the
siting of the homes on the lots. The positioning of the front
entrances near the center of the modules, as previously explained,
has in most designs, required that the lengthened modules be sited
parallel to the front lot line. This is necessary to avoid the
alternative positioning at 90 degrees to the front lot line, which
would place the front entrance adjacent to the side lot line and
thereby provide inadequate visibility from the street. Further, the
lengthened modules require wider lots, which inherently increases
the infrastructure cost of the lots. Also, the present lengthened
modules are not compatible with the concept of clustered housing on
smaller lots, which is being promoted today in order to reduce
housing costs. The clustered housing concept requires housing
products that can more effectively utilize the depth of the lots
without placing the front entrances adjacent to the side lot
lines.
[0015] The HUD-code home and modular housing industries of today
have evolved from a combination of the mobile home industry of the
1950's and on-site construction. Planning, with the assistance of
computers, has enabled module producers to offer a range of
customization within the above-described constraints. Although the
production of the modular homes occurs in the controlled
environment of a plant, the homes are still constructed with
conventional materials, in much the same way as in the mobile home
industry of the 1950's and the frame construction of site-built
homes.
[0016] The evolution of the modular production process has occurred
without recognizing and utilizing the accomplishments and
techniques of the automotive industry. A new approach could find
new techniques, solve the problems created by the limitations
discussed above, and enhance all aspects of the housing products
while reducing costs.
[0017] By recognizing and utilizing advances in the automotive
industry, the scale of the planning component in the housing
industry can be increased from the historic 2.times.4 wood stud to
a functional module. Accordingly, an object of the present
invention is to provide a completely new approach to the structure
for roofing modules that will overcome most of the previously
discussed limitations, and to allow the development of standardized
spatial modules of varying functional and utilitarian use, and
modules that could be selected and composed by the consumer so as
to create unlimited house designs.
[0018] Partial solutions to the above-identified problems were
developed by the present inventor in U.S. Pat. No. 6,681,544, which
issued on Jan. 27, 2004 and U.S. Pat. No. 6,705,051, which issued
on Mar. 16, 2004. Due to the advances disclosed and claimed in
these patents it is now possible to realize more efficient modular
home designs to fit narrower lots, and higher density land
development, thereby lowering street and utility infrastructure
costs. Stronger steel homes can resist higher winds, and
refrigeration type insulation can greatly reduce energy costs. This
accomplishment will allow production builders in the United States
to shift from current high cost and time consuming building
practices, thereby lowering their costs by converting to
industrialized totally mechanized, high quality modular
housing.
SUMMARY OF THE INVENTION
[0019] An object of the present invention is to provide a modular
housing system that can satisfy the public's desire for higher
pitched roofs, provide historic aesthetics, and convert the
industry's present wood trusses, which wasted volumes of costly
space, to usable and accessible attic storage and bedrooms.
[0020] The system employs the present inventor's flat shipped,
panel roof, which is rolled up into place by a crane while setting
the modules at the job site, accomplishes this entire transition.
Converting the modular roof system from trusses to closed and open
flat panel components simplifies the entire modular structure. This
enables true industrialization and mass production of every major
flat panel component composing a modular house on one CNC (computer
numerical control) encoder driven work table, consuming only 3300
square feet of plant floor area. As demonstrated in FIG. 1, the
necessary plant size is significantly less in comparison with the
typical wood modular plant. In the present invention, the work
table is connected to an overhead tram, which transports the
finished panels to the assembly table where all the panel
components, which compose the module, are assembled.
[0021] The work table is equipped with major telescoping transverse
encoder driven tools, and is powered by an overhead tram with three
material supply bridges and encoder driven material placement
systems (see FIG. 3). The supply bridges are loaded with materials
directly from four truck trailers by the plant's overhead crane
system. The materials have been temperature tempered, by over-night
storage in the plant for immediate panel production.
[0022] The open panels (OP) and closed panels (CP) when assembled,
create housing modules constructed with cold formed steel rolled
shapes (CFSRS). The framing for floors, roofs, gables and wall
panels, are all produced on the single CNC Encoder Driven Work
Table. The closed panel sub-components are assembled into finished
housing modules in the plant, and are shipped on boggy wheels and
erected by a crane at the building site. The closed panels (CP)
include the following materials: steel framing (CFSRS), gypsum
panels (GP), oriented strand board (OSB) or Plywood (PLWD), cement
bonded particle board (CPB), sanitary piping, water piping,
sprinkler piping, heat ducts, ventilation ducts, wiring harnesses
and high R-value, foamed insulation. The modular housing system
includes a 48' CNC driven work table and a 120' overhead tram with
three powered material supply bridges. Two tables can be installed
in a 38,500 square foot plant (see FIG. 2). With the inventive
modular system, in a period of four days, the module interior and
exterior can be completely finished, and then assembled on site by
a crew of four men to produce a two-story 1800 square foot home
having a two-car garage in four days.
Panel Production Center
[0023] The panel production center includes the following four
major, control integrated components (see FIGS. 3-4).
[0024] (1) Central Computer Controller
[0025] (2) CNC Driven Work Table "WTAB"
[0026] As shown in FIG. 5, the work table includes two longitudinal
76 foot linear encoder tracks above the table top, and ten actuator
heads, eight transverse 10 foot linear encoder tracks and actuator
heads, and eight vertical encoded actuators, or eight synchronized
motor cylinders beneath the table top.
[0027] (3) Three Material Supply Bridges on an Overhead Power Tram
(OPT)
[0028] As shown in FIGS. 6-7, three material bridges are provided
on an overhead power tram (OPT). The material bridges are color
coded for production communication, for example, the three material
supply bridges include a Green Bridge for supplying sheeting and
transporting the sheeting; a Blue Bridge for supplying steel and
transporting the steel; and the Red Bridge for supplying adhesive
and insulation.
[0029] (4) Four Major Telescoping Linear Encoded Transverse Tools
(TLETT)
[0030] The third component of the panel production system includes
routers, material locators, nailers, and diamond saws (see FIG.
8).
[0031] Module Component Assembly Table (MAT)
[0032] The modular housing system also include a panel assembly
center comprising a module component assembly table (MAT), which
has an assembly encoder lift and a hold hi-bay provided with four
hoists and two bridges. The module component assembly table also
includes an exterior and interior wall panel lift and position
apparatus which has four hoists and two bridges.
[0033] The novel modular housing system can be arranged in two
forms, i.e., a standard semi-mechanized manual system which is
contemplated to be primarily used in under-developed nations in
which the cost of labor is low; and an optional totally mechanized
system applicable primarily in developed nations in which the labor
costs are relatively high.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Embodiments of the invention will now be described by way of
example only with reference to the accompanying drawing in
which:
[0035] FIG. 1 is a schematic top plan view comparing the area of a
conventional modular plant with the area of a plant constructed in
accordance with the present invention;
[0036] FIG. 2 is a schematic top plan view of a plant constructed
with two production lines and indicating the potential production
capability;
[0037] FIG. 3 is an illustration of the four major control
integrated functions of the production center of the present
invention;
[0038] FIG. 4 is a perspective view of the production center and
assembly center of the modular housing system;
[0039] FIG. 5 is a perspective view of a worktable constructed in
accordance with the present invention with material and transverse
tool locators;
[0040] FIG. 6 is a perspective view showing the three material
supply bridges supported on an overhead tram;
[0041] FIG. 7 is a perspective view of the three material supply
bridges shown in FIG. 6 with the bridges loaded with materials for
constructing panels;
[0042] FIG. 8 is a perspective view of the worktable and the four
major telescoping transverse tools;
[0043] FIG. 9 is a schematic illustration of the central computer
controller;
[0044] FIGS. 10 and 11 are perspective views illustrating
production procedures 1 and 2;
[0045] FIGS. 12 and 13 are perspective views illustrating
production procedure 3;
[0046] FIGS. 14 and 15 are perspective views illustrating
production procedure 4;
[0047] FIGS. 16 and 17 are perspective views illustrating
production procedures 5 and 6, respectively;
[0048] FIGS. 18 and 19 are perspective views illustrating
production procedure 7;
[0049] FIGS. 20 and 21 are perspective views illustrating
production procedure 8;
[0050] FIG. 22 is a perspective view illustrating production
procedures 9 and 10;
[0051] FIG. 23 is a perspective view illustrating production
procedure 11;
[0052] FIG. 23A is a perspective view illustrating a wall panel
layout for a typical module;
[0053] FIG. 24 is a perspective view showing a single rectangular
framed panel;
[0054] FIG. 25 is a perspective view showing a sheeting layout of a
single rectangular framed gable following production procedures 9
and 10;
[0055] FIGS. 26, 27 and 28 are perspective views of a telescoping
linear encoded diamond saw cutting a steel frame into gable panels
in production procedure 11;
[0056] FIG. 29 is a perspective view showing the cut gable frame
being reinforced with steel angles in production procedure 11;
[0057] FIG. 30 is a perspective view showing the application of
exterior finish material in production procedure 11;
[0058] FIG. 31 is a perspective view showing the roll over of the
cut gable frame using a rollover device in production procedure
11;
[0059] FIG. 32 is a perspective view showing the process of
transporting the gable frame, produced in production procedure 11,
to the module assembly table;
[0060] FIG. 33 is a perspective view illustrating production
procedure 12;
[0061] FIG. 34 is a perspective view of the process of dissecting
the singular rectangular framed gable and final gable positioning
prior to installation;
[0062] FIG. 35 is a perspective view illustrating the final folding
position of the gable panels prior to roof panel final
placement;
[0063] FIG. 36 is a perspective view illustrating the process of
fastening roof ridge lift hinges to the roof panels;
[0064] FIG. 37 is a perspective view illustrating the process of
installing roof rollers to slidably attach the roof panels to an
attic floor panel;
[0065] FIG. 38 is a perspective view illustrating the process of
testing the roof panel sub assembly;
[0066] FIG. 39 is a perspective view illustrating the process of
storing the roof panel sub assembly following completion of the
testing shown in FIG. 38;
[0067] FIG. 39A is a perspective view of first floor panel,
interior, exterior and marriage wall panels in a stacked position
on the assembly table;
[0068] FIG. 40 is a perspective view of the module assembly table
after transporting of the completed panels forming the module
envelope;
[0069] FIG. 40A shows typical wall panel junctures;
[0070] FIG. 41 is a perspective view illustrating lifting procedure
3 at the module assembly table;
[0071] FIG. 42 is a perspective view showing the roof panel sub
assembly being lowered onto the module's bearing walls to complete
the module assembly at the module assembly table;
[0072] FIG. 43 is a perspective view showing the completed module
assembly being transported by the plant overhead crane system;
[0073] FIG. 44 is a schedule of the major procedures performed at
the worktable for producing walls and ceilings; and
[0074] FIG. 45 is a schedule of the major procedures performed at
the worktable for producing floors and roofs.
DETAILED DESCRIPTION OF THE INVENTION
[0075] The work table (WTAB), shown in FIG. 5, supports thirteen
(13) major production procedures and several minor procedures. The
major procedures are performed in a numerical sequence, and the
specific procedures that are performed on a particular panel is
dependent on the type of panel being produced. Thus, not all of the
procedures are necessary for each panel, and, depending on the
panel, some of the procedures are omitted. See the schedules
"System Procedures Walls & Ceilings" and "System Procedures
Floors & Roofs" for single family homes. The schedules include
17 panel types, which enable the modular housing system to
construct homes of all types, and code approved modules for
construction of apartments, motels, and commercial structures, one
through four stories, which can be increased by creating hybrid
panels.
[0076] The term "CC" or "CCC" used herein refers to control by the
operator at the CNC Central Computer in a glassed booth that is
preferably located adjacent to the front of the Work Table (see
FIG. 9). The modular housing system requires a 48 foot work table
and single framed panel widths of 5'9.5" through 15'9.5" and panel
lengths from 2' through 48'. Two wall panels can be produced
simultaneously in any combination of interior or exterior widths of
7'9.5".
[0077] Single wall panels, limited by first floor module shipping
heights, can be produced at, ceiling heights of 9'5.5". Multiple
Panels can be produced, the sum of the lengths not to exceed 48'
and sawn to their designed installed lengths by the Diamond Saws
(STLEDS). The exterior finishes of Wall Panels & Gable Panels
are applied on the Module Component Assembly Table (MAT).
[0078] The work table's eight telescoping pylons tubes (TPT) can be
driven horizontally by a transverse mechanical actuator system
(MAS) or a linear encoder motor (LEM) beneath the surface of the
work table. The synchronized movement of the pylon tubes is normaly
equal distance from their storage positions toward the center of
the work table. The transverse motion is controlled independently
for each side of the work table and may be varied to accommodate
asymmetric panel configurations. The "CCC" establishes the panel
width being produced. This movement carries the reinforced
longitudinal linear encoder track with electromagnets (LLETM) and
its encoder actuator heads (EAH) on the telescoping pylon tubes
(TPT) in the transverse motion.
[0079] The encoder actuator heads (EAH) are normally parked at the
front of the work table and the initial movement to the
longitudinal Center, less than 1/2 of the panel length being
fabricated, is controlled by the operator at the CNC Central
Computer (CCC). This movement locates the front of the panel to
start fabrication and centers the panel on the work table (WTAB), x
and y axis. Thereafter the incremental movement is controlled by
the operator at the CNC Central Computer (CCC) and the panel
computer program, but is activated by the equipment trained
controllers (ETC) on the work table operating the supply bridges on
the overhead power tram (OPT).
[0080] The head of the eight pylons and the linear encoder tracks
are raised and lowered by synchronized motor cylinders (SMC), or
vertical encoded actuators (VEA), which locate the vertical
position of the longitudinal linear encoder track (LLETM), enabling
various production functions (see Procedures for Floors & Roofs
and Walls & Ceilings, Pylons Vert. Ref.).
[0081] The encoder actuator heads (EAH) positioning, on both the
left and right sides of the worktable is controlled by the operator
at the CNC central computer (CCC), who locates all of the
transverse reference lines about the longitudinal axis of the work
table. This is consistent for all work procedures, including the
x-axis of the transverse telescoping linear encoder (TTLE), which
locates the Y-axis of all openings in the field of panels being
produced on the work table.
[0082] The computer numerical control (CNC) driven work table
(WTAB) is of modular design and can be extended in 13 foot
increments to lengthen panels produced and thereby increasing the
module length capability of the system.
[0083] The base structure of the work table is recessed 72 inches
below the plant's main floor. This maintains the top of the table
elevation at 18 inches above the plant floor and conceals the
transverse linear encoded motors (TLEM) and the base of the motor
cylinders. This further provides access for maintenance and space
for dirt and dust collection systems beneath the table. Access to
this space is a basement door and steps in the plant floor at the
rear of the work table.
Three Powered Supply Bridges on Overhead Power Tram (OPT)
GREEN--Sheathing, BLUE--Steel, RED--Adhesive & Insulation
[0084] The Overhead Tram is supported on two rows of 10 inch
tubular steel columns; spaced 20 feet on center (see FIGS. 4, 6 and
7). Each row is 13 feet 7 inches from the longitudinal axis of the
table. The columns support three 10 inch tubular steel beams
parallel to the work table. The tubes are bolted to the head of the
columns and separated to receive energy chain systems (ECS) that
power and provide encoder control systems to the three supply
bridges spanning over the work table (WTAB). Each of the three
bridges moves independently and parallel to the longitudinal axis
of the table.
[0085] The supporting arms of the bridges are each independently
supported on an inverted steel angle track mounted on top of the
three longitudinal tubular steel beams.
[0086] The green sheathing bridge, blue steel bridge, and red
adhesive/insulation bridge are designed so that they may each cross
over or under each other in the performance of their independent
production procedures without interfering with each other. The
bridges may also move to their point of origin for restocking
beyond the front of the work table, or to a temporary parking place
in preparation of their next scheduled procedure. This allows for
the production of multiple panel types, which require alternate
procedures, in varying sequence. The three supply bridges, with
cross-over or under capability permit thirteen production
procedures in any order. Also, hybrid structural panels are
constructed of multi-layered structural members and varied sheeting
materials as shear layers and bonded by adhesives and pin
fastenings.
[0087] The tram extends beyond the rear of the work table to
provide temporary parking space for the three supply bridges. The
green bridge tram rail continues to the module assembly table (MAT)
to enable transport of finished panel components for assembly.
[0088] The front of the work table provides a home base for each of
the supply bridges to be loaded by the plant's overhead crane
system (POCS), directly from four loaded trailer trucks positioned
in the plant.
[0089] Berths for the four major supply trailers (STIP) are
provided to achieve temperature and moisture stability of the
materials prior to inclusion in the production procedures (see
Procedures for Floors & Roofs, and Walls & Ceilings).
[0090] Each of the bridges are connected by the tram to electric
power and control wiring for (1) welding, (2) press joining of
metal, and (3) attachment by screw guns and other tools at the
point of material placement. Each bridge is equipped with the tools
required to complete the installation of the materials being
transported. The control wiring allows the integration of optional
encoder driven sub-systems, which will increase the speed of
material placement and fastening thereby reducing the number of
equipment trained controllers (ETC) on line.
[0091] Procedures 1, 9 & 12
[0092] The Green Bridge (Sheeting & Transport) is equipped with
standard manual motor and vacuum assisted sheet placement, as shown
in FIG. 10, and is also available with an optional encoder driven
system, which advances the Green Bridge by incremental sheeting
panel widths and an encoder driven slide mechanization, which
slides the top sheet, from sloping or a ( flat pallet, which is not
shown) to its placement parallel or perpendicular to the
longitudinal axis on the work table (WTAB). Also, in procedure 9,
the top sheet is slid onto the top of the steel frame (see FIG.
22). The Green Bridge in Procedure 12 transports the panel
components to the module component assembly table (MAT) (see FIG.
32). The Green Bridge is equipped with encoder vertical adjustment
to permit clearance of standard and hybrid panels of varying
thickness and the dispensing of sheeting materials for all panel
heights.
[0093] Procedures 4 & 7
[0094] The Blue Bridge (steel) is equipped with transverse steel
members (standard manual dispensing) hand-held & automatic
welders, metal press joining equipment, and screw guns. The Blue
Bridge is also available with an optional encoder driven system,
which advances the Blue Bridge concurrently with the encoder
actuator heads (EAH) on the longitudinal encoder track (LLETM) and
mechanically dispenses the cold formed steel members (TFM), e.g.
floor joists, ceiling joists, roof joists, wall studs, and gable
studs, into the locator arm of the encoder actuator heads (EAH)
material holder (see FIGS. 14 and 18). Mechanized welders, metal
press joining equipment, and screw guns fasten the steel members
(TFM) to the panel edge beams, intermediate beams, or wall track,
thereby automating the steel member (TFM) fastening.
[0095] Procedures 5 & 8
[0096] The Red Bridge for applying adhesive and insulation is
equipped with standard hydraulic controller platforms and manually
operated adhesive and insulation placement devices (see FIGS. 16
and 20). It is also available with an optional encoder driven
system, which advances the Red Bridge automatically in accordance
with steel member (TFM) location data stored at the central
computer control (CCC). The hydraulic platforms are fitted with
transverse linear encoder driven tracks and encoder activator heads
for transporting and activating the adhesive nozzles and insulation
spray heads which are equipped with optical laser depth sensors to
apply the insulation materials between and adhesives on top of the
framing members.
[0097] Four Major Telescoping Linear Encoded Transverse Tools
[0098] As shown in FIG. 8, the four major telescoping tools include
routers, material locators, nailers, and diamond saws. Each of the
four major telescoping tools are composed of two structural
components with interlocked sliding bearing surfaces, which permits
each tool to contract and expand in length to accommodate panel
widths controlled by the pylon's (TPT) positioning of the
longitudinal linear encoder track (LLETM) establishing the panel
widths. The telescoping feature also allows additional length
contraction and expansion of each tool controlled by the
independent encoder positioning of the encoder actuator heads (EAH)
on each of the longitudinal linear encoder tracks (LLETM), which
permits skewing of the tools (e.g. see FIG. 26) to perform angular
operations of routing, locating, nailing, and sawing.
[0099] Each of the tool's two structural components is equipped
with parallel encoder locators that drive the power tools the
length of the structural component and overlapping each other's
function. To perform a continuous unbroken operation, the encoder
actuator heads (EAH) adjust to maintain an uninterrupted function,
compensating for the combined thickness of the tool's two
structural components.
[0100] Each of the power tools encoder locators, measure
independently from the encoder actuator heads (EAH) on the
longitudinal linear encoder tracks (LLETM) toward the center of the
work table (WTAB).
[0101] Procedures 2 and 11
[0102] The routers (TTLER) in procedure 2 (see FIG. 10) rout
openings in the bottom sheeting, which is installed in procedure I
work table. The openings include windows, doors, stair openings,
mechanical, electrical, plumbing, access panels and other
miscellaneous openings.
[0103] As shown in FIG. 23, procedure 11 includes routing openings
in the top sheeting which is installed in procedure 9. This
procedure is similar to procedure 2.
[0104] Procedures 7 and 10
[0105] Material locators (TTEL) in procedure 7 locate and display
callout for fastening mechanical, electrical, plumbing and other
miscellaneous devices to steel framing and aligning with openings
routed in procedures 2 and 11.
[0106] In procedure 10, following the nailer (TTLEN), the
transverse telescoping encoded locators (TTEL) mark the location of
all interior wall panels on the closed floor panel (CP) sheeting,
which was installed in procedure 9.
[0107] As shown in FIG. 22, the nailers (TTLEN) in procedure 10,
which follows procedure 9, locate and nail top sheeting to the
steel frame.
[0108] Procedure 11G
[0109] Diamond saws (STLEDS) in procedure 11G saw cuts skewed
angled gables and other metal framing as required in the
fabrication process (see FIGS. 26, 27 and 28).
Panel Steel Edge Beams (EB) & Intermediate Beams (IB)
[0110] Two Blue Bridge welding systems (BWSB) and two welding
stations (BWS) are employed in the process of fabricating the edge
beams and the intermediate beams (see FIG. 13).
[0111] The edge beams and intermediate beams are fabricated of two
C-shaped joists (CFSR), welded flange to flange, top and bottom,
with the 15/8" flange member toward the outside of panel and a 2"
flange member toward the inside of panel. This creates a 35/8" wide
beam and by placing the (CFSR) members to counter align the web
openings, and increased beam strength is realized.
[0112] Mounted on Blue Bridge are two welding systems (BWSB) and
two suspended welding stations (BWS). The Blue Bridge transports
the C-shaped cold formed rolled steel members (CFRS), temporarily
clamped together and suspended beneath the Blue Bridge, to the work
table where they are fastened electro-magnetically to the inner
face of each of the longitudinal encoder tracks (LLETM). As shown
in FIG. 13, the beam fabrication process takes place on the work
table at the beam welding station (BWS).
[0113] The pylons (TPT) raise the linear encoder tracks (LLETM) 12"
above the work table surface and the beam welding station (BWS),
which is suspended beneath the Blue Bridge, is lowered and placed
on the linear encoder tracks (LLETM) encoder actuator heads (EAH),
which drive and position the beam welding station (BWS)
intermittently welding, simultaneously the top and bottom flanges
to create the finished end beams (EB) and intermediate beams (IB).
When the welding is completed, the beam welding stations (BWS) are
retracted to the bottom of the Blue Bridge.
[0114] The central computer activates the pylons of the work table
to raise the linear encoder tracks (LLETM) and the panel edge beams
(EB) to the working height to begin the placement of the transverse
framing members (TFM).
[0115] The welding of the end beams (EB) and intermediate beams for
an entire days panel production can be produced off shift, and
temporarily stored at the front of the work table to enhance the
daily module output.
Procedures 1 & 9--Green Bridge Sheeting Installation
[0116] The green bridge is operable to place the closed panel (CP)
bottom and top sheeting materials, i.e. gypsum panels (GP),
oriented strand board (OSB) and cement bonded particle board (CPB).
In procedures 1 and 9, the pylons on the transverse axis of the
worktable locate the inner face of the longitudinal linear encoder
tracks (LLETM) at the outside dimension of the steel frame. This
prepares the worktable to receive the panels of sheeting. The
purchased lengths of sheeting are normally equal to the outside
dimension of edge beams of the steel frame (less positioning
tolerance), but may be reduced to apply higher compressive bearing
materials under increased loading.
[0117] Sheeting is received on flat bed trailers, which are parked
in the plant. The pallets are composed of 20 to 30 sheets of gypsum
or other sheeting materials, 4'-0" wide.times.purchased lengths and
of varying thickness (3/8" thru 11/8"). The sheeting materials, in
procedure 1 (FIG. 10) with their finish side in the down position
and in procedure 9 (FIG. 22) with their finished side in the up
position, are lifted by the plant overhead crane using modified
pallet lifters and stocked on the live green bridge. The Green
Bridge is activated by "controllers" moving from the front toward
the rear above the worktable. As shown in FIG. 10, the Green Bridge
is suspended from the tram rails that extend parallel to the
longitudinal axis of the worktable, and is powered by variable
speed electric power drives (EPD) on each track of the inner rail
of the tram.
[0118] The controllers activate vacuum assist slides, shifting the
sheeting off and onto the worktable (Procedure 1) or steel framing
(Procedure 9), the ends of the sheeting panels are positioned in
line with the surface of the longitudinal linear encoder tracks
(LLETM) thereby placing the bottom or top sheeting of the closed
panel (CP).
Procedure 4--Closed Panel Steel Framing
(Edge Beams, Intermediate Beams, Transverse Framing Members,
Blocking)
[0119] Single Closed Panel Framing Procedure:
[0120] The central computer (CC) activates the pylons (TPT) to
raise the pylon heads to the framing height above the worktable
(WTAB). This is normally 32 inches above the table top, but can be
adjusted to a higher setting within the range of the 471/4" stroke
of the synchronized motor cylinders (SMCS) or vertical encoded
actuators (VEA) depending on the workers' height to provide a
comfortable working range.
[0121] As shown in FIG. 14, single panels are framed by two
workers, i.e., equipment trained controllers referred to herein as
ETC's. The two ETC's activate the incremental movement of the
encoder actuator heads (EAH) on the HD049 or longitudinal linear
encoder tracks (LLTEM) locating and supporting transverse framing
members (TFM) and blocking until they are screwed in place, to the
longitudinal edge beams (EB) and intermediate beams (IB). The edge
beams (EB) are magnetically attached and supported by the
longitudinal linear encoder tracks (LLTEM) on the telescoping pylon
tubes (TPT).
[0122] Each ETC completes the screw or press metal fastening of the
transverse framing member (TFM) on each side of the panel and the
encoder actuator heads (EAH) are activated to the next framing
position, to allow for variations in the time required for each ETC
to complete work in his area of responsibility. A lockout is
required, until the work is completed, by the second ETC.
[0123] There are conditions when the transverse framing members
(TFM) do not extend so as to bear on the edge beam (EB) at one side
of the panel, but will frame into an intermediate beam (IB)
creating panel openings for stairs, HVAC trunk ducts, etc.
Temporary supports are placed beneath the intermediate beams (IB)
until the framing about the opening is completed.
[0124] This will require the ETC on one side of the worktable to
override the lockout to activate the HD049 or encoder actuators
heads (EAH) and enable the placement of transverse framing members
from his side of the table. A positioning laser located on the
HD049 or encoder actuator heads (EAH) is used to position the
interior setting of the framing members into the intermediate beam
(IB).
[0125] The standard framing system of transverse framing members
(TFM) is 24 inches on center, additional framing members are
located by the HD049s or the encoder heads (EAH) at different
spacing to accommodate various structural conditions and interior
panel dissection during the erection procedure of the interior wall
panels. Blocking, which is screw attached between the framing
members (TFM), is located by the transverse telescoping encoder
locators (TTEL) following the encoder actuator heads (EAH).
[0126] The two ETC's work overtop of the transverse framing members
(TFM) to screw attach the clip angles to the edge beams (EB). The
clip angles are preinstalled on the transverse framing members
(TFM) off of the worktable using the press metal joining at each
end of the framing member maintaining overall length tolerance.
[0127] Double Closed Panel (2) St'd 7'-91/2".times.48'-0" Wall
Panels Int. or Ext. Framing Procedure
[0128] Double wall panel fabrication is performed by four workers
on the worktable. This includes two ETC's, one adjacent to each of
the HD049s or encoder actuator heads (EAH) and two assemblers in
the center of the worktable. One worker is located on each side of
the four stanchions, which rise from beneath the surface of the
worktable, supporting a continuous steel plate parallel to the
longitudinal axis of the worktable. The steel plate will support
electromagnetic clamps to anchor the top structural tracks, which
receive the studs. Stanchions, when activated by central controller
(CC), maintain the same height as the telescoping pylon tubes
(TPT). The wall panels are fastened by press metal, joining the
steel studs to the steel track, with equipment suspended from
overhead and supported by the Blue Bridge.
Procedure 7--Mechanical & Electrical Sub Assembly
Installation
[0129] (Piping Sub Assemblies (PSA), Duct Sub Assemblies (DSA),
Electric Power Harnesses (EPH), and Cable Harnesses (CH))
[0130] FIG. 18 shows the ETC's performing the seventh procedure in
which pre-assembled mechanical and electrical power distribution
and devices are installed in panels on the worktable. Sanitary
piping, water supply piping, sprinkler piping, referred to herein
as piping sub assemblies (PSA), are assembled in jigs and air
tested, prior to positioning them at the end of the worktable. The
piping sub assemblies (PSA) drain in the direction of the
longitudinal axis of the flat panels, and longitudinal edge beams
(EB) permit front or rear module connections to all utilities.
[0131] Heating and air conditioning ducts and ventilation ducts,
referred to herein as duct sub assemblies (DSA) are completed in
jigs and air tested, prior to positioning them at the end of the
worktable. The duct sub assemblies (DSA) are engineered to
distribute main air supply parallel to the longitudinal axis of the
flat panels framed with intermediate beams (IB) and sub transverse
distribution parallel or through the open webs of the steel joists.
Grommets and patented anchoring devices are used to protect
electrical and mechanical components.
[0132] Wiring harnesses are assembled on a wiring fixture,
including switches, outlets and electrical junction boxes referred
to herein as electric power harnesses (EPH). Security cables,
network cables, telecomm cables referred to herein as cable
harnesses (CH) are assembled off of the worktable. The electric
power harnesses (EPH) and cable harnesses (CH) are coiled on roll
off spools and placed at the end of the worktable.
[0133] Starting at the control end of the worktable the piping sub
assemblies (PSA), duct sub assemblies (DSA), electric power
harnesses (EPH) and cable harnesses (CH) will be fed through the
open webs of the end edge beams (EB). As the ETC's place the
transverse framing members (TFM) and screw them into place, the
ETC's also place grommets and pull the mechanical and electrical
sub assemblies through the open webs of the transverse framing
members (TFM). The securing of these assemblies to the framing in
their final location is not performed until the frame system is
lowered and set in the adhesive on the bottom sheeting material.
The material locators (TTEL) mark and call out on the screen
instructions relating to the assemblies as they are secured in
place by the ETC's.
[0134] Mechanical and electrical sub assemblies are clamped and
fastened to the frame. Sub assemblies are installed through the
openings previously routed in the bottom panel (GP). Piping is
installed to drainage specifications and branch piping is extended
in the transverse directions parallel to the transverse framing
members (TFM) to the open webs of the edge beams (EB) to serve
adjacent modules. Plumbing and duct outlet risers are extended to
the bottom level of the next top application of a panel (OSB or
GP).
Procedures 5 & 8--Application of Adhesives & Insulation
[0135] Procedure 5: RED BRIDGE applies Urethane Adhesives
[0136] In this procedure, the completed structural frame is lowered
by the central controller (CCC). Then the synchronized motor
cylinders (SMC) or vertical encoder actuators lower the pylons and
steel frame to a height of 11/2 inches above the bottom sheeting.
As shown in FIG. 16, two suspended work platforms, for supporting
two ETC's, are lowered beneath the bottom of the Red Bridge. The
ETC's stand on the platforms and apply the adhesive, with hand-held
wands, from the Red Bridge. The adhesive beads are applied to the
sheeting in a pattern mirroring the frame. Two types of urethane
adhesives, a high early strength and a long term high strength, are
applied to the sheeting. This provides for early handling of the
closed panels (CP). Once the adhesive application is completed, the
pylons are again actuated and powered by the central controller
(CCC), imbedding the steel frame into the adhesive on the upper
surface of the bottom sheeting.
[0137] Procedure 8--Red Bridge Applies Urethane and Icynene Foam
Insulation
[0138] As the red bridge moves from the rear toward the front, the
ETC's install the urethane and icynene foam insulation from the
suspended platforms (see FIG. 20). The insulation is pumped under
pressure from dispensing systems located on the overhead red bridge
in order to fill the panel cavities to achieve specified insulation
R-Values.
[0139] Procedure 8--Red Bridge Applies Urethane Adhesive
[0140] Also, in the eighth procedure (FIG. 21), beads of long term
high strength adhesives are placed on top of the edge beams (EB)
and transverse framing members (TFM) from the rear to the front in
preparation of procedure 9, i.e. placing the top sheeting (OSB,
GP).
Roof Panel Sub Assembly (RPSA)
(1 Attic Floor Panel, 4 Gable Panels, 2 Roof Panels)
Assembling: the Roof Panel Sub Assembly (RPSA)
[0141] As shown in FIGS. 32 and 33, panels composing the roof panel
sub assembly are produced on the worktable (WTAB) in the order of
assembly, on the module assembly table (MAT). The attic floor panel
is transported by the Green Bridge and centered on the module
assembly table (MAT).
[0142] As shown in FIG. 34, a single rectangular framed gable
(SRFG) is produced on the worktable (WTAB) and is partially cut by
the skewed telescoping linear encoded diamond saws (STLEDS) into
the four gable panels (GAP) (see FIGS. 26, 27, 28). The (ETCS)
reinforce the cut gable frame with screwed in place steel angles
(see FIG. 29). The (SRFG) finish siding material is installed on
the worktable (see FIG. 30). The four gable panels remain attached
as a single rectangular framed gable (SRFG) to be inverted after
Procedure 11G by the roll over (RTPT) on the worktable (see FIG.
31). The gable panels (GAP) will remain attached until they are
transported by the Green Bridge to the module assembly table (MAT)
and placed on top of the attic floor panel, with the exterior
finish side in the down position where they will be dissected to be
sandwiched between the roof panels and the attic floor panel (AFP)
in their final roof roll-up position. The two ETC's press join
additional steel angles to the back of the single rectangular
framed gable (SRFG), and cut free the four gable panels (GAP)
permitting relocation of the gable panels on the attic floor (FIG.
34), to assume the slide out position during the roll-up roof
procedure.
[0143] Two roof panels (ROPA) are produced and transported either
as one or, two separately, if the sum of the total length exceeds
the work table (WTAB) production capability of 48 feet. The Green
Bridge places the roof panels on top of the four gable panels
(GAP), and returns to the worktable (WTAB).
[0144] As shown in FIG. 36, roof ridge lift hinges (RRLH) are
inserted between the two roof panels, from the top and screwed in
place. The hinges provide attachment rings for the hoists to raise
the roof during tests on the module assembly table (MAT) and raise
the roof during field installation of the module. The hinges are
removed after the raised panels are braced and screw attached to
the top of the gable tracks and the roof tail joist stops (RTJS)
are screw attached to the ends of the attic floor panel (AFP). The
hinges are returned to the plant for reuse.
[0145] The two ETC's in FIG. 36 fold down, reversed assembly hinges
that are preinstalled on the worktable (WTAB) at the inside of the
roof panel rake beam (RPRB). The hinges are screw fastened to the
roof panel and fastened at the assembly table at the top of the
gable panels (GAP).
[0146] The roof panel sub assembly (RPSA) is raised by four hoists
on the encoder lift and hold hi-bay (ELHH). The roof panel sub
assembly is lifted to a height of 6 feet, thereby providing the
necessary clearance for the ETC's standing under the flat roof
panel extension, to insert and snap in place four modular housing
roof rollers (RR) at four roof tail joists (see FIG. 37). The roof
rollers connect the roof panels at the juncture of the attic floor
panel on each end of the roof panels. The roof rollers are rolled
tight to the end of the attic floor panel (AFP), where the anchor
plates are screw attached to the end of the attic floor panel
(AFP). The roof rollers are disclosed in U.S. Pat. No. 6,681,544,
which is incorporated by reference herein.
Testing the Roof Panel Sub Assembly (RPSA)
[0147] As shown in FIG. 38, the assembled roof panel sub assembly
(RPSA) is lowered to the top of the module assembly table (MAT),
and the attic floor is anchored to the module assembly table. Then,
as shown in FIG. 39, the encoder lift and hold hi-bay centers a
crane bridge and one hoist over the roof ridge lift hinges (RRLH),
and lifts the roof sub assembly to roll up the roof and verify
dimensional accuracy. Once the test is completed, the attic floor
is detached and the roof panel sub assembly (RPSA) is reconnected
to four hoists on two crane bridges of the encoder lift and hold
hi-bay and hoisted to the overhead storage space and safety blocked
by the turn-outs mounted on the four tubular columns.
Module & Wall Panel Assembly
[0148] (First or Second Floor Panel, Interior Walls Panels,
Exterior and Marriage Wall Panels) As shown in FIG. 23a, module
panels are produced on the worktable (WTAB) and transported to the
module assembly table (MAT) by the Green Bridge. The module floor
panel is centered on the module assembly table (MAT). The double
closed panel (CP) composed of interior wall panels (IWP) are
transported second, as a single panel by the Green Bridge. The
interior wall panels (IWP) are unloaded in the flat position
centered on the middle of the floor panel. The double closed panels
(CP), composed of exterior and marriage wall panels (EMWP) are the
last produced on the worktable (WTAB), and are transported by Green
Bridge to be positioned on top of the interior wall panels (IWP)
and are to be the first erected. The completed panels that have
been transported to the module assembly table (MAT) are shown in
FIG. 39A & FIG. 40.
[0149] As the double closed panels (CP) are positioned in the flat
position, they are dissected longitudinally, forming two linear
multi-panels (LMP), composed of one longitudinal exterior wall
panel (LEWP) joined at the top and bottom track, to one transverse
exterior wall panel (TEWP) and one longitudinal marriage wall panel
(LMWP) joined at the top and bottom track, to one transverse
exterior wall panel (TTEWP; see FIG. 39A & FIG. 40).
[0150] Lifting Procedure 1: Wall Panel Lift and Position (WPLP)
(see FIG. 40)
[0151] The lower crane way with Bridge #1 and #2 and two hoists,
lifts the joined longitudinal exterior wall panel (LEWP) and the
transverse exterior wall panel (TEWP) to a vertical position and
places the bottom (OSB) extension of the longitudinal exterior wall
panel (LEWP) over the longitudinal edge of the floor panel to be
screwed in place. The joined transverse exterior wall panel (TEWP)
is cantilevered beyond the end of the floor panel. The hoist on
Bridge #2 is reconnected to the center of the transverse exterior
wall panel (TEWP) and the top and bottom plate is cut free,
allowing the transverse exterior wall panel (TEWP) to be turned 90
degrees and installed on the transverse end of the floor panel.
[0152] Steel angle plates are screwed in place to complete the 90
degree joint of the longitudinal exterior wall panel (LEWP) and the
transverse exterior wall panel (TEWP), thereby permitting the
un-coupling of the Bridge #1 from the longitudinal exterior wall
panel (LEWP).
[0153] Lifting Procedure 2 (see FIG. 40)
[0154] This Procedure is a mirror image of Lifting Procedure 1, and
includes substituting a longitudinal marriage wall panel (LMWP) for
the longitudinal exterior wall panel (LEWP).
[0155] Lifting procedures 1 and 2 complete the exterior envelope of
the module.
[0156] Lifting Procedure 3
[0157] The interior wall panels (IWP) are produced as one linear
multi-panel (LMP) on the worktable (WTAB). The linear multi-panel
(LMP) is composed of a series of short interior wall panels (IWP)
joined by a common top and bottom track to be dissected
incrementally during erection. The interior wall panels (IWP) are
positioned in the linear multi-panel (LMP) in the order of erection
within the module envelope. Typical Interior Wall Panel (IWP) panel
junctures and connections are illustrated in FIG. 40A.
[0158] As shown in FIG. 41, the lower crane way (WPLP) with Bridge
#1 and #2 and two hoists lifts the linear multi-panel (LMP) to a
vertical position, stabilizing the top, and lowers the bottom track
to temporary support blocks, located between the points of interior
wall panels (IWP) dissection. Two ETC's will handle the dissected
interior wall panels (IWP) with manual tools and screw anchor them
in place (see FIG. 40A--Typical Panel Junctures).
[0159] During the interior wall panels (IWP) erection, the ETC's
complete the electrical and mechanical connections of the installed
systems in the panels during production on the worktable
(WTAB).
[0160] Lifting procedure 3 completes the interior panel
installation and then the panels are screw anchored to the
floor.
[0161] Setting the Roof Panel Sub Assembly (RPSA)
[0162] As shown in FIG. 42, the roof panel sub assembly (RPSA) is
lowered by the four hoists on the encoder lift and hold hi-bay
(ELHH) and is supported on temporary blocking on top of the
module's bearing walls. This operation is performed to allow the
ETC's to pull down electrical cables stubbed off in the bottom of
the attic floor panel, to connect to junction boxes in the module's
wall panels and also attach HVAC and mechanical connections to the
like systems in the module's wall panels.
[0163] Once this operation is complete, the roof panel sub assembly
(RPSA) is raised, the blocks are removed and the roof panel sub
assembly (RPSA) is lowered to its final bearing position on the
bearing walls. The final structural connections are made by screw
fastening steel plates to the attic floor panel and the module's
envelope bearing walls.
[0164] During the entire module assembly, four electrified
articulated jib arms extending from the tube columns provide
counter-balanced screw guns, press joining tools, steel nibbler
cutting, and other miscellaneous tools used in the performance of
the work.
[0165] Installing Module Exterior Finish Material
[0166] Concurrent with Lifting Procedure 3, the ETC's perform
preliminary work on the exterior wall panels leading to the
application of the exterior finishes which will begin at the first
module completion station on the final assembly finishing line.
Following the installation of the exterior finish material, the
plant overhead crane (POCS) transports the assembled module to the
final assembly finishing line.
[0167] The preceding description is of a preferred embodiment of
the present invention, however, it should be understood that the
same is not limited thereto but is susceptible to numerous changes
and modifications as will be apparent to one of ordinary skill in
the art. Accordingly, the scope of the invention is not to be
limited to the details shown and described herein, and is intended
to cover all modifications which are encompassed by the scope of
the appended claims.
* * * * *