U.S. patent application number 10/824165 was filed with the patent office on 2005-10-20 for truss manufacturing method and system.
Invention is credited to Kardosz, Timothy J., Zuniga, Martin J..
Application Number | 20050229528 10/824165 |
Document ID | / |
Family ID | 35094814 |
Filed Date | 2005-10-20 |
United States Patent
Application |
20050229528 |
Kind Code |
A1 |
Kardosz, Timothy J. ; et
al. |
October 20, 2005 |
Truss manufacturing method and system
Abstract
Methods and systems are provided for making one or more
structural stud trusses without the need for using a jig when the
truss is assembled. In one embodiment, data identifying a plurality
of structural stud members for making the truss is generated. The
data includes data for each stud including physical stud parameters
and one or more locations for an alignment guide where another
member is to connect with it. A roll forming machine is controlled
with the generated data to produce the plurality of stud members
whereby the roll forming machine applies one or more alignment
guides onto each member based on locations identified in the
generated data. Finally, after all or some of the stud members are
formed, the members are assembled to form the truss using the
alignment guides to align connecting members with each other in
order to fasten them together.
Inventors: |
Kardosz, Timothy J.; (San
Marcos, TX) ; Zuniga, Martin J.; (Blanco,
TX) |
Correspondence
Address: |
MICHAEL O. SCHEINBERG
P.O. BOX 164140
AUSTIN
TX
78716-4140
US
|
Family ID: |
35094814 |
Appl. No.: |
10/824165 |
Filed: |
April 14, 2004 |
Current U.S.
Class: |
52/639 |
Current CPC
Class: |
E04C 3/11 20130101 |
Class at
Publication: |
052/639 |
International
Class: |
E04B 001/32 |
Claims
We claim as follows:
1. A method of making a truss, comprising: generating data
identifying a plurality of structural stud members for a truss, the
structural stud members to be formed from a roll forming machine,
the data for each stud including physical stud parameters and one
or more locations for an alignment guide; controlling the roll
forming machine with the generated data to produce the plurality of
metal stud members, the roll forming machine applying one or more
alignment guides based on the locations in the data; and assembling
the studs to form the truss, the act of assembling including using
the alignment guides to align connecting members to each other in
order to fasten them together.
2. The method of claim 1, wherein the one or more studs are "C"
channel metal studs.
3. The method of claim 1, wherein the act of applying the one or
more alignment guides includes punching a hole in a stud at each
alignment guide location.
4. The method of claim 3, wherein the act of securing connecting
stud members includes inserting a peg into one or more sets of
associated alignment holes as they are fastened together with one
or more screws.
5. The method of claim 1, further including controlling the roll
forming machine to apply an identifier proximal to each alignment
guide indicating how many fasteners are to be used at the
connection corresponding to the alignment guide.
6. The method of claim 1, wherein the truss is a back-to-back truss
comprising "C" channel structural steel studs.
7. The method of claim 1, wherein the data is generated by an
executing software module that receives as input information
generated by a design program that at least partially designs the
truss.
8. A truss made in accordance with the method of claim 1.
9. In a roll-forming system that includes a roll forming machine
and a processor for generating data to control the roll-forming
machine to create a plurality of metal stud members for making a
truss, a memory media having instructions that when executed by the
processor cause it to perform a method comprising: receiving data
that identifies the plurality of stud members and where they are
connected to one another to form the truss; and generating data for
controlling the roll-forming machine to create the studs, the
generated data causing the roll-forming machine to apply an
alignment guide on each stud at a location where it is to be
connected to another stud.
10. The memory media of claim 9, wherein the roll-forming machine
is controlled to punch a hole for each alignment guide.
11. The memory media of claim 9, wherein the roll-forming machine
is controlled to apply an assembly tag onto each member proximal to
an alignment guide.
12. The memory media of claim 9, wherein an alignment guide is
placed on a member's centerline where it intersects with a
centerline from a connecting member.
13. A kit for making a truss, comprising: one or more chord members
formed using structural studs each having a web portion; and one or
more web members formed using structural studs each having a web
portion, the chord and web members each having an alignment guide
located on its web portion where it is to connect with another
chord or web member thereby enabling the truss to be assembled
without the need for a jig.
14. The kit of claim 13, wherein the chord members have flange
portions that oppositely face flange portions on the web members
when the chord and web members are connected together to form a
truss.
15. The kit of claim 13, wherein the chord and web member
structural studs are formed from "C" channel studs.
16. The kit of claim 13, wherein the web and chord members have
assembly tags next to the alignment guides.
17. The kit of claim 13, wherein the alignment guides are formed
from holes punched out of the web portions.
18. The kit of claim 17, wherein the holes are non-rotatable
holes.
19. The kit of claim 13, wherein the structural stud members are
formed out of light gauge steel roll using a roll form machine.
20. A truss formed from the kit of n claim 13.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention generally relates to methods and
systems for making trusses. In particular, it relates to a method
and system for making trusses out of metal members without the need
for using an alignment jig.
BACKGROUND OF THE INVENTION
[0002] Metal trusses are used for both commercial and residential
structures. They are typically formed either from structural stud
members or a combination of structural stud, non-structural stud
and track members. Structural studs have cross-sectional profiles
that provide them with structural stability; tracks generally have
"U" shaped profiles that allow them to receive stud members fixed
in a conventional. perpendicular configuration for making frame
sections; and non-structural studs have profiles that give them
reduced structural support but make them amenable for other
functions such as receiving other studs.
[0003] Different design types such as frame and back-to-back
trusses are commonly used for roofing and floor applications. Frame
trusses are similar to wall frames except that they have a
roof-shaped profile rather than a rectangular wall shape. They have
upper and lower tracks with parallel, vertically oriented stud
members sandwiched between the tracks to provide structural support
for the roof material. They are relatively easy to make because
they employ conventional wall framing methods, which have been
honed over the years and allow for the manufacture of many
different frames in an efficient manner. For example, in one known
method, a roll-forming machine automatically produces the entire
set of tracks and studs required for one or more trusses in a
relatively short amount of time. (Roll forming machines are used to
make both studs and tracks from rolls Of light-gauge steel (e.g.,
24 to 14 gauge) by bending and cutting the metal coil into studs
and/or tracks with appropriate lengths and channel dimensions.) The
tracks have pre-punched fastener holes, spaced apart on their
flanges, for receiving the studs, which have corresponding
pre-punched holes. This allows the frame assemblers to quickly
position and fasten the studs to the tracks by using the fastener
holes to not only fasten the studs to the tracks with screws or
rivets, but also to align the studs within the track. One drawback,
however, is that frame trusses are limited in their span and load
capabilities and are less efficient in terms of the amount of stud
material needed within each truss for supporting a given load.
[0004] Back-to-back trusses, on the other hand, are generally
better in terms of their load carrying capability and they can span
much larger openings. This is so because they use structural studs,
such as "C" channel or other structural studs, connected
back-to-back without the use of tracks and because they use
triangulated web members, rather than just vertically oriented
studs, which provide added stability and support for the same
amount of stud material. Unfortunately, however, such back-to-back
trusses are more difficult to design and assemble because of their
more complicated web member configurations. As with frame and other
metal trusses, roll-form machines can be used to efficiently
generate the stud members used for the back-to-back trusses, but
assembling the members into the trusses is more difficult,
especially when different truss types are being assembled. For each
truss type, a jig (or pattern) is typically fabricated based on an
assembly drawing. The jig, which is normally made from heavier
steel, is used for aligning truss members as a truss is being
assembled, one truss at a time. It holds the members in place while
an assembler inserts self-drilling screws at each node where
members connect with each other. This can be efficient when a large
number of trusses of a given design are made. Unfortunately, when
trusses of many different designs are to be made, this method
breaks down because an excessive amount of time is required for
creating a separate jig for each different truss design.
[0005] Accordingly, what is needed is an improved method for making
trusses.
SUMMARY OF THE INVENTION
[0006] Methods and systems are provided for making one or more
structural stud trusses without the need for using a jig when the
truss is assembled. In one embodiment, data identifying a plurality
of structural stud members for making the truss is generated. The
data includes data for each stud including physical stud parameters
and one or more locations for an alignment guide where another
member is to connect with it. A roll forming machine is controlled
with the generated data to produce the plurality of stud members
whereby the roll forming machine applies one or more alignment
guides onto each member based on locations identified in the
generated data. Finally, after all or some of the stud members are
formed, the members are assembled to form the truss using the
alignment guides to align connecting members with each other in
order to fasten them together.
[0007] A kit is also provided for making a truss. In one
embodiment, such a kit includes one or more chord members and one
or more web members. The one or more chord members are formed using
structural studs that each have a web portion. Similarly, the one
or more web members are formed using structural studs that each
have a web portion. The chord and web members also each have an
alignment guide located on their web portions where they are to
connect with another chord or web member thereby enabling the truss
to be assembled without the need for a jig.
[0008] The foregoing has outlined rather broadly the features and
technical advantages of the present invention in order that the
detailed description of the invention that follows may be better
understood. Additional features and advantages of the invention
will be described hereinafter. It should be appreciated by those
skilled in the art that the conception and specific embodiment
disclosed may be readily utilized as a basis for modifying or
designing other structures for carrying out the same purposes as
the present invention. It should also be realized by those skilled
in the art that such equivalent constructions do not depart from
the spirit and scope of the invention as set forth in the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a more complete understanding of the present invention,
and the advantages thereof, the following description is made with
reference to the accompanying drawings, in which:
[0010] FIG. 1A is a side profile view of a conventional roof truss
made in accordance with an embodiment of the present invention.
[0011] FIG. 1B is an end profile view of a CEE channel stud
member.
[0012] FIG. 1C is an enlarged view of area "A" from FIG. 1A.
[0013] FIG. 2 shows a tag portion of a truss member made according
to one embodiment of the present invention.
[0014] FIG. 3 is an exploded view of a connection between
connecting truss members in accordance with an embodiment of the
present invention.
[0015] FIG. 4 is a block diagram of a system for making trusses
according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] With reference to FIGS. 1A-1C, an exemplary roofing truss
100 made in accordance with an embodiment of the present invention
is shown. Truss 100 is a conventional roof truss made from
roll-formed, structural stud members connected in a back-to-back
configuration. It generally comprises a lower C-channel chord
member 102, upper C-channel chord members 104, 106, and C-channel
web members 101 to 117. The centerlines for each member are shown,
along with connection nodes N1 to N18.
[0017] Truss 100 is a conventional roof truss formed, e.g., from
light gauge (22 to 12 .ga) steel stud members, but it is formed
using techniques of the present invention and takes advantage of
features available on conventional roll-forming machines. Namely,
the machine is used not only to form and cut each truss member into
its proper dimensions, but also, it applies an alignment guide at
each part of a member that is connected to another member. An
alignment guide, as used herein, can be anything such as a mark,
feature, detent, recess, protrusion, hole, or the like that is used
for aligning two or more members together at a particular desired
location where they are to be connected to each other. The use of
alignment guides makes it easier and more efficient to assemble
stud members into a truss because it eliminates the need to use a
jib for aligning and possibly securing the members as they are
being fastened to each other. Instead, with the assistance of one
or more persons, the alignment guides serve to accurately position
the members relative to each other and with some alignment guides,
secure them in place as they are being connected together, e.g., by
a person with a self-driving screw gun. In one embodiment, the
alignment guides are placed on the members at their connection
nodes by a roll-forming machine used to form the members.
[0018] With continuing reference to FIG. 1A, nodes N1 to N18, along
with the centerlines for each member, are shown. A node occurs
where two or more members are connected together and typically
occurs at the intersection of the centerlines of the connecting
members. However, nodes do not always occur at centerline
intersections. For example, in some cases, nodes may be offset in
an appropriate direction to place an alignment guide on a member
when little space exists at the centerline intersection point. In
other cases, as a matter of design choice, the nodes may simply be
placed at overlapping portions of connecting members but not
necessarily at the intersection of their centerlines. With truss
100, a node (such as N3) may be offset when a member has
insufficient space at a connection area as a result, e.g., of a
relatively sharp angle between itself and the member to which it is
being connected.
[0019] FIG. 1B shows an end view of a "C" (or CEE) channel stud
used for implementing the stud members in truss 100. A "C" stud is
a structural stud typically formed from bending a metal strip with
a roll forming machine to give it its web, flange, and lip
portions, as shown in the drawing. The lip portions give the studs
their added structural support quality in contrast with tracks,
which have negligible or no lips. Light gauge steel roll is
typically used but other suitable materials could also be used for
making the "C" studs used in these trusses. A conventional
roll-forming machine, such as a Knudson KS-246A FRAMEMAKER.TM. roll
forming machine, can be used for making "C" studs out of light
gauge steel roll. A single roll forming machine can typically make
all of the members needed for one or more trusses of a given
design. They have components for cutting the members into different
lengths and tools for bending the steel into studs having different
desired channel dimensions. In fact, depending on the particular
truss design, most trusses will have web and chord members with
different lengths and channel dimensions. In one embodiment, the
truss members are formed as C-channel studs having various lengths
and fixed lip and flange dimensions of 0.5" and 1.625",
respectively but with web widths that can range from 2.5" to 12" in
width. However, persons of ordinary skill will recognize that the
specific dimensions for each member will depend on the particular
truss design, as well possibly on the truss design software used
for designing the truss and available materials for building the
truss.
[0020] With reference to FIG. 1C, in one embodiment, holes are used
as alignment guides. FIG. 1C shows an enlarged view of area "A" in
truss 100 in FIG. 1A. With this type of alignment guide, a hole is
created (e.g., punched out) at each node so that a peg (or dowel)
can be inserted into overlapping holes of connecting members to
temporarily hold and align them to one another as they are
connected together with fasteners such as screws. Depicted in FIG.
1C are the fastener connections 122 and alignment guide holes 124,
corresponding to nodes N7 and N8, for aligning and securing web
members 109 and 111 to chord member 106 wile connecting the members
to each other with screws 122. In this embodiment, the pegs are
used to temporarily hold connecting members in place while they are
connected. Screws 122 actually fix them together for operation in
the truss. Any suitable fasteners can be used for connecting them
together. Fasteners can include but are not limited to rivets,
screws, bolts, weld joints, spots or clinches and the like. In the
depicted embodiment, self-driving, #10 screws for light-gauge steel
are used. In the connections at nodes N7 and N8, four screws 122
are used. The total number for each connection, however, may vary
depending upon the truss design. As addressed below, in one aspect
of the present invention, the number of screws is indicated near
the alignment hole to make it more convenient for the
assembler.
[0021] In the depicted embodiment, holes (with the assistance of
pegs or dowels) are used as the alignment guides. However, the
present invention is certainly not limited to such guides. Any
suitable guide such as an indention, dimple, fastener, or the like
could also be used. One advantage of holes, however, is that they
can readily be applied at or near a node with conventional
roll-forming machines that have tools for punching holes that are
otherwise used, e.g., for wiring and piping.
[0022] FIG. 2 shows an end portion of a C-channel, truss member 201
formed by a roll forming machine such as the one mentioned above.
It includes an assembly tag 202 and alignment hole 204. With
various embodiments of the present invention, assembly tags are
used to assist assemblers in laying out the constituent truss
members to form a truss as they are emitted from the roll forming
machine. With the use of assembly tags and a general understanding
of the particular truss design, one or more assemblers can quickly
lay out the truss members without the need of a jig or even an
assembly drawing of the truss. The assembly tag 202 has a length
identifier 206, truss identifier 208, member identity identifier
210, and screw count identifier 212. The length identifier 206
indicates the length of the member. In the depicted identifier 206,
the value "8-2-8" is given. The first number, 8, is in feet, the
second number, 2, inches, and the third number, 8, in sixteenths of
inches. Accordingly, the length identifier in this example
indicates that this member is 8 feet and 2.5 inches. The truss
identifier 208 identifies the truss for a given lot. In many
applications, members for numerous trusses are made from a single
roll forming machine on a single occasion, so this identifier (T1
in the figure) identifies the particular truss in the lot for which
the member belongs. The member identity identifier 210 indicates
the connection nodes (15-16 in the drawing) at either end of the
member. That is, this identifier indicates that the member is to be
located between the identified nodes (nodes 15 and 16 in this
example). The screw count identifier 212 identifies the number of
screws to be mounted proximal to the alignment hole (204) that is
next to the tag.
[0023] With conventional roll-forming machines such as the one
discussed above, assembly tags such as 202 in the depicted figure
can be printed onto a member at a desired location as the member is
being formed. Thus, with appropriate control (discussed in greater
detail below), a conventional roll-forming machine can create truss
members with assembly tags and alignment holes without the need for
additional equipment. Moreover, it can do this in a timely manner
to produce truss members that can be assembled more efficiently
than with traditional methods such as jigs.
[0024] FIG. 3 is an exploded view of a connection between
connecting truss members 301, 303 in accordance with an embodiment
of the present invention. The web and chord member 301, 303 are
connected in a back-to-back configuration with the members' web
portions adjacent to one another and their alignment holes 305
aligned with one another.
[0025] A dowel (or peg) 304 is inserted into the associated
alignment holes 305 to secure members 301 and 303 while they are
fastened together with self-driving screws 302. The "back-to-back"
connection shown in this figure is applied to all web/chord member
connections for the truss in FIG. 1A, which makes it a
back-to-back, C-channel truss. While a circular hole and peg
cross-section are used for the depicted alignment guide, other
suitable shapes and schemes could also be used within the teachings
of the present invention. For example, a non-rotatable (e.g.,
square, triangle, oval) shape could be used. Such a non-rotatable
shape allows for more precise member alignment, i.e., it allows for
members to be positioned together at precise angles without the
need for other members to be in place. An oval alignment hole is
well-suited as such an alignment guide because it is non-rotatable
and it can be applied with a conventional roll forming machine by
punching several holes overlapping one another. (Of course, other
desired shapes can readily be used simply by providing a roll
forming machine with a punch or cutting tool capable of making the
desired shape.) In some embodiments, matching guides can also be
used to ensure that assemblers connect the proper members at their
proper locations. Matching guides are unique (or reasonably unique)
in shape or size for each different connection node. This prevents
assemblers from making improper member connections.
[0026] FIG. 4 shows a system 400 for making trusses according to
one embodiment of the present invention. System 400 can be used to
design trusses and automatically generate the members for forming
the trusses. System 400 generally includes computer 405, interface
module 410, roll-form machine controller 420, and roll-form machine
425. Computer 405 is used to receive or generate truss design data
based on information and instructions received from a user. It may
generate drawings and other data describing a truss, and it also
generates data identifying the lengths and channel dimensions for
each member in the truss. The roll-from machine controller 420
controls the roll-form machine 425 to automatically generate the
truss members, and the interface module 410 processes the cut-list
data to put it in a form that is readable by the machine controller
420 for it to control the roll-form machine 425 to make the truss
members. It also includes data or instructions that cause
appropriate alignment guides to be placed on the members.
[0027] The depicted computer 405 has a truss design program 407
that when executed by computer 405, can assist a designer in
designing a truss for a particular need. In one embodiment, the
truss design program is Keymark's KeyTruss.TM. software package
that automates the analysis and design of back-to-back C-channel
steel trusses. The use of such a program makes it easier to design
a truss that conforms with standards defined by the AISI (American
Iron and Steel Institute) with regard to cold forming steel
framing. With the KeyTruss.TM. program, a user can input a truss
profile specifying member lengths and positions, and the software
determines the dimensions for each member based on available member
a dimensions as designated by the user. The program can also
generate a drawing file (such as an AutoCad.TM. type DXF file),
along with detailed material lists and cut sheets (e.g., ROL file)
for individual or multiple trusses.
[0028] In one embodiment, the interface module 410 uses data from
one ore more of these generated files to generate a control file
for forming the constituent members and applying to them alignment
guides for assembly of the trusses. It uses data from the truss
design program 407 and outputs control files that are suitable for
execution by the roll-form machine controller 420. The interface
module comprises one or more software modules, patches, functions,
routines, and/or programs running on computer 405, controller 420,
a separate computer or processor, or a combination thereof. In the
depicted embodiment, interface module 410, when executing, performs
routine 412. Routine 412 includes the steps of receiving truss
parameters from the design program at step 414, determining
alignment guide locations for truss members at step 416, and
generating control data for controlling the roll forming machine to
form the truss members at step 418. there are many suitable ways to
perform the functions of routine 412. For example, they could be
performed by a separate program running on computer 405 or on a
separate processing machine. They could also be performed by a
patch, plug-in or module designed to execute in cooperation with
the truss design program 407.
[0029] Similarly, there are numerous suitable ways to perform the
functional steps. In one embodiment, alignment guides are placed at
nodes defined by member centerline intersections. From truss
geometry data (which it can obtain from the truss design program or
from another program if no truss design program is used), interface
module 410 determines node locations for each truss member based on
centerline intersections. It then generates (or modifies) a control
file for execution by roll-form machine controller 420. In one
embodiment, a patch, executing with the truss design program 407 to
transform truss member cut list data (e.g., from a KeyMark.TM.
".rol" format) into a suitable machine controller format is
enhanced (or augmented with another patch) to include this node
location data to cause the machine to also punch an alignment guide
hole in the nodes on the truss members. In another embodiment,
further functionality is included that alters node locations when
it is determined that the node is too close to the edge of a
member. Interface module 410 may also generate controller file data
for causing a an assembly tag such as the one discussed above to be
applied to each member.
[0030] The roll-form machine controller 420 and roll-form machine
425 operate in cooperation with one another to automatically
generate the members for a truss. Any suitable combination of
conventional devices can be used to implement these components. In
one embodiment, the roll-form machine is a Knudson KS-246A
FRAMEMAKER.TM. roll forming machine, and the controller 420 is an
AMS.TM. XL200 Series Controller, which is designed specifically for
controlling forming machines such as the Knudson roll-forming
machine.
[0031] With this controller, a command file in an appropriate
format (e.g., ".del" format) can be uploaded into the controller
and used to control operation of the roll-forming machine 425. It
should be recognized, however, that numerous other combinations of
compatible controllers and roll-forming (or other stud
manufacturing) machines could also be used.
[0032] With system 400, many trusses of the same or different
designs can be manufactured in a reasonable amount of time. The
truss members can be assembled almost as fast as they are produced
by the roll-form machine. With the elimination of the need for an
alignment jig, not only can many different truss designs be
assembled in a small amount of time, but also, assembly can occur
at a construction site, as well as in a shop or factory.
[0033] The present invention and its advantages have been described
in detail, but it should be understood that various changes,
substitutions and alterations can be made herein without departing
from the spirit and scope of the invention as defined by the
appended claims. Moreover, the scope of the present application is
not intended to be limited to the particular embodiments of the
process, machine, manufacture, composition of matter, means,
methods and steps described in the specification.
[0034] For example, while trusses using C-channel stud members were
primarily discussed, other suitable stud designs (including
proprietary designs) could certainly be used in accordance with the
teachings of the present invention. Similarly, the trusses of the
present invention are not limited to just roof trusses but could
include trusses for any application including floor trusses.
Likewise, while back-to-back structural stud trusses were primarily
addressed, the manufacture of other truss design types could be
enhanced with the principles set forth herein. As one of ordinary
skill in the art will readily appreciate from the disclosure of the
present invention, processes, machines, manufacture, compositions
of matter, means, methods, or steps, presently existing or later to
be developed that perform substantially the same function or
achieve substantially the same result as the corresponding
embodiments described herein may be utilized according to the
present invention. Accordingly, the appended claims are intended to
include within their scope such processes, machines, manufacture,
compositions of matter, means, methods, or steps.
* * * * *