U.S. patent application number 11/707555 was filed with the patent office on 2007-11-15 for overhead gantry for use in building panel construction.
Invention is credited to Giuseppe Corrado Aprile, Michael J. Churchill, Vincent D. Mifsud, Michele Tancredi.
Application Number | 20070262040 11/707555 |
Document ID | / |
Family ID | 38537936 |
Filed Date | 2007-11-15 |
United States Patent
Application |
20070262040 |
Kind Code |
A1 |
Mifsud; Vincent D. ; et
al. |
November 15, 2007 |
Overhead gantry for use in building panel construction
Abstract
The disclosed technology enables manufacturers to efficiently
design and manufacture structural wall panels, floor panels and
roof panels from cold-formed steel for use in residential and
commercial construction. The panels are individual components that
can be installed at a building site to form a structure that
includes walls, floor and a roof. Structures may be manufactured in
a manufacturing facility and delivered to a construction site for
installation.
Inventors: |
Mifsud; Vincent D.;
(Oakville, CA) ; Aprile; Giuseppe Corrado;
(Burlington, CA) ; Churchill; Michael J.;
(Oakville, CA) ; Tancredi; Michele; (St. George,
CA) |
Correspondence
Address: |
GOODWIN PROCTER LLP;PATENT ADMINISTRATOR
EXCHANGE PLACE
BOSTON
MA
02109-2881
US
|
Family ID: |
38537936 |
Appl. No.: |
11/707555 |
Filed: |
February 16, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60791982 |
Apr 14, 2006 |
|
|
|
Current U.S.
Class: |
212/324 ;
52/745.02; 52/745.2; 52/747.1; 52/749.1 |
Current CPC
Class: |
B23P 21/004 20130101;
Y10S 706/923 20130101; B21F 27/128 20130101; B23P 19/04
20130101 |
Class at
Publication: |
212/324 ;
052/745.02; 052/745.2; 052/747.1; 052/749.1 |
International
Class: |
B66C 5/02 20060101
B66C005/02 |
Claims
1-60. (canceled)
61. An apparatus for transporting a panel for use in metal frame
building construction, comprising: a first track; a support member
movably coupled to the first track; at least two support arms
coupled to the support member; and a lifting member coupled to a
distal end of each of the at least two support arms, wherein each
lifting member is configured to engage an edge of a panel, and
wherein the at least two support arms are moveable with respect to
each other such that the lifting members can lift and support the
panel in a substantially horizontal orientation.
62. The apparatus of claim 61, wherein the first track is moveably
coupled to at least one second track.
63. The apparatus of claim 61, wherein a longitudinal axis of the
at least one second track is substantially perpendicular to a
longitudinal axis of the first track.
64. The apparatus of claim 62, comprising two second tracks.
65. The apparatus of claim 64, wherein the two second tracks
support the first track at its distal ends.
66. The apparatus of claim 62, comprising two support arms.
67. The apparatus of claim 62, wherein a means of moving the at
least two support arms with respect to each other comprises a
manual mechanism.
68. The apparatus of claim 62, wherein a means of moving the at
least two support arms with respect to each other comprises a
powered mechanism.
69. The apparatus of claim 68, further comprising a control
system.
70. The apparatus of claim 69, wherein the control system can
control the movement of the at least two support arms.
71. The apparatus of claim 70, wherein the control system can
further control the movement of the support member.
72. The apparatus of claim 71, wherein the control system can
control the movement of the first track with respect to the at
least one second track.
73. The apparatus of claim 71, wherein each lifting member is
configured to engage the edge of the panel from below.
74. The apparatus of claim 62, wherein the first track and the at
least one second track are configured to enable a panel to be
transported to any point within a plane defined by a limit of
travel of the support member and the first track.
75. The apparatus of claim 62, wherein the at least one second
track is coupled to a roof of a building.
76. The apparatus of claim 62, wherein the at least one second
track is supported by a plurality of pillars.
77-133. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
provisional patent application Ser. No. 60/791,982 filed Apr. 14,
2006, the disclosure of which is being incorporated herein by
reference in its entirety. This application is related to U.S.
patent application Docket No. GTP-001, U.S. application Ser. No.
11/707,650, entitled "Material Transport System for Building Panel
Assembly," U.S. patent application Docket No. GTP-002, U.S.
application Ser. No. 11/707,638, entitled "Framing Table for
Building Panel Assembly," U.S. patent application Docket No.
GTP-003, U.S. application Ser. No. 11/707,563, entitled
"Bi-Directional Roller Table," U.S. patent application Docket No.
GTP-004, U.S. application Ser. No. 11/707,649, entitled "Automatic
Pinning Process for Building Panel Assembly," U.S. patent
application Docket No. GTP-006, U.S. application Ser. No.
11/707,645, entitled "Tools and Methods for Designing a Structure
Using Prefabricated Panels," U.S. patent application Docket No.
GTP-007, U.S. application Ser. No. 11/707,765, entitled
"Information Technology Process for Prefabricated Building Panel
Assembly," U.S. patent application Docket No. GTP-008, U.S.
application Ser. No. 11/707,637, entitled "Kit for Manufacturing an
Enclosure from Prefabricated Panels," U.S. patent application
Docket No. GTP-009, U.S. application Ser. No. 11/707,646, entitled
"Component Manufacturing System for a Prefabricated Building
Panel," and U.S. patent application Docket No. GTP-010, U.S.
application Ser. No. 11/707,561, entitled "Manufacturing Method for
a Prefabricated Building Panel," all filed of even date herewith,
the disclosures of which are being incorporated herein by reference
in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
building construction, and more particularly to methods and
apparatus for the design, construction and transport of
prefabricated panels for steel frame building construction.
BACKGROUND OF THE INVENTION
[0003] Conventional building construction has many problems, not
the least of which is the time and expense required to construct a
structure, such as a multi-story home or office building. Much
construction work is custom work that is performed on-site, and so
is subject to a variety of inefficiencies. New methods for
construction are needed to alleviate the problems with current
techniques.
[0004] One method of construction that addresses a number of the
limitations of traditional building construction is the use a
prefabricated panels, constructed from steel and/or other
appropriate materials. These panels can be constructed offsite
before being shipped to the construction site and assembled into a
building. The construction and organization of these panels may,
however, be complicated in itself. As a result, many of the
expected advantages of the use of prefabricated panels in building
construction have not been fully realized, especially with respect
to the systematic management and control of construction of a
building from initial design stage to final assembly.
SUMMARY OF THE INVENTION
[0005] In general, in one embodiment, the disclosed technology
enables manufacturers to design and manufacture structural wall
panels, floor panels and roof panels from cold-formed steel for use
in residential and commercial construction. The panels are
individual components that can be installed at a building site to
form a structure that includes walls, floor and a roof. Structures
can be manufactured in a manufacturing facility and delivered to a
site for immediate construction.
[0006] One attribute of certain embodiments is that they use
cold-formed steel raw materials instead of traditional wood and
concrete construction methods. There are several advantages to the
structures that result from the disclosed technology both to the
builders and to the consumers that live or work in these
structures. The advantages to the builders are stronger buildings
that can withstand hurricane conditions and significant seismic
forces, increased speed of construction, improved quality of
construction which reduce after sales service costs, safer
construction due to the use of non-combustible materials, and less
on-site labor to construct these projects. The benefits to the
consumers that live in these homes or work in these buildings are
better energy performance, environmental benefits due to use of
recycled steel, homes that last longer, and better indoor air
quality, to name just a few.
[0007] In one embodiment, the manufacturing process includes use of
a computer-aided design software application that is integrated
with enterprise management software. The design software is used to
develop the design for a building. Information from the design
software is provided to enterprise software that is used to control
and manage the production line and fabrication process for each of
the components. The fabrication includes using steel in the form of
steel coil, which is cut to length and assembled into panels that
are used to construct the floor, walls, and roof of a building,
which might be, for example, as tall as six stories.
[0008] One aspect of the invention may include a process for
manufacturing a structure. This process includes receiving a design
for a structure and creating a model of the structure comprised of
panels, wherein the panels comprised of cold-formed steel, in
response to the design. The process further includes generating, in
response to the model, specifications for panels, bills of
materials for panels, panel fabrication drawings, and panel
installation drawings, managing manufacture of each of the panels
in a manufacturing facility according to the bill of materials and
the fabrication drawings, and collecting in the manufacturing
facility the panels and other parts for delivery.
[0009] In one embodiment, the process can further include
transporting the panels and other parts to a construction site,
and, at the construction site, assembling the panels into a
structure according to the panel installation drawings.
[0010] Another aspect of the invention can include a manufacturing
system for manufacturing a steel structure. This manufacturing
system can include a computer-aided design (CAD) system for
creating a model of a building structure by generating
specifications for panels, bills of materials for panels, panel
fabrication drawings, and panel installation drawings, and a
manufacturing enterprise management system for managing manufacture
of each of the panels according to the specifications and the
fabrication drawings.
[0011] In one embodiment, the manufacturing system can further
include a material optimizer for cutting material and forming the
metal into a part of a panel according to the specifications, and a
material handling system including a tray, conveyor, and rails for
collecting parts, including parts formed by the material optimizer,
for assembly as described in the fabrication drawings. The
manufacturing system can also include a pre-fastener for fastening
parts into a subassembly as described in the fabrication drawings,
a framing table for assembling parts and/or subassemblies into a
panel as described in the fabrication drawings, and a sheathing
table for applying a coating or covering to the panel as described
in the fabrication drawings.
[0012] In one embodiment, the manufacturing system can further
include an overhead gantry system, including a crane and a grabbing
device for holding an assembled panel and collecting panels for
delivery.
[0013] One aspect of the invention can include a material transport
system for use in building panel assembly for metal frame building
construction. The material transport system includes a rail system
including at least one starting location and at least one end
location, at least one tray adapted to travel along the rail
system, wherein the tray is adapted to carry construction elements
for assembly into a metal frame building panel, and at least one
work station located on the rail system.
[0014] In one embodiment, the at least one work station can include
at least one of a tray loading station, an inventory check station,
a test station, a monitoring station, a pre-weld station, a
sub-assembly station, an assembly station, a post-weld station, and
a sheeting station. The rail system can be adapted to deliver one
or more construction elements to an assembly station. The system
can include at least one starting location and a plurality of end
locations. The rail system can include at least one junction
connecting the at least one starting location to the plurality of
end locations. Each of the plurality of end locations can include
an assembly station. The assembly station can include a framing
table.
[0015] In one embodiment, the starting location can include a tray
loading station. The rail system can include a plurality of
rollers. In one embodiment, the tray can include at least one
rolling element. The tray can be manually moved along the rail
system. The movement of the tray along the rail system may also be
gravity assisted. In another embodiment, the tray may be
automatically moved along the rail system.
[0016] The material transport system can further include a return
leg adapted to return a tray to the starting location. The return
leg can include a track located below the rail system.
Alternatively, the return leg can include a track located above the
rail system. The return leg may be one of an automatic, a manual,
and a gravity assisted return leg. In one embodiment, the starting
position can include an elevator element adapted to move the tray
from the return leg to the rail system.
[0017] One aspect of the invention can include a framing table for
use in building panel assembly for metal frame building
construction. The framing table can include at least two panel
supports. The panel supports can include a support structure, a
transport element mounted to an upper portion of the support
structure and configured to enable slideable movement thereon, and
at least one side bar mounted to an upper portion of the support
structure. The at least one side bar may be configured to at least
partially position a building panel during assembly. The framing
table can further include at least one track supporting at least
one of the at least two panel supports, wherein the at least one
track can be configured to enable relative movement between the at
least two panel supports in at least one horizontal axis, and
wherein a least one element of the building panel is supported by
the at least two panel supports during assembly.
[0018] In one embodiment of the invention, the framing table can
further include a control system. In one embodiment, moving at
least one of the at least two panel supports on the at least one
track enables the construction of building panels of different
dimensions. The framing table may be configured to support a
building panel of up to 24 ft by 24 ft.
[0019] In one embodiment, each of the at least two panel supports
may be supported by at least one track. The at least two panel
supports may be supported by the same at least one track.
Alternatively, the at least two panel supports may be supported by
different tracks. The at least one side bar may be configured to
provide a compression force on the building panel during
assembly.
[0020] In one embodiment, the framing table can further include at
least one hydraulic lift. The at least one hydraulic lift may be
configured to enable vertical movement of at least one of the at
least two panel supports. The at least one hydraulic lift may be
configured to enable simultaneous vertical movement of the at least
two panel supports.
[0021] In one embodiment, the framing table can further include at
least one screw gun coupled thereto. The at least one screw gun may
be manually operated. Alternatively, the at least one screw gun may
be automatically operated in response to a signal from the control
system. In one embodiment, the transport element comprises a
plurality of rollers. The transport element on the at least two
panel supports may be configured to enable an assembled panel to be
slideably removed from the framing table.
[0022] Another aspect of the invention can include an apparatus for
the bi-directional transport of construction materials for use in a
material transport system. This bi-directional transport apparatus
can include a table, a first roller set mounted to the table and
configured to support the construction materials on the table, and
a second roller set mounted to the table, wherein the second roller
set is movable between a first position below a plane defined by
the first roller set and a second position above the plane defined
by the first roller set. The bi-directional transport apparatus can
further include a moving element for moving the second roller set
between the first position and the second position, wherein raising
the second roller set to the second position allows the second
roller set to support the construction materials on the table.
[0023] In one embodiment, the first roller set may be configured to
support the construction materials in a first direction of travel,
and the second roller set may be configured to support the
construction materials in a second direction of travel. The first
direction of travel may be substantially perpendicular to the
second direction of travel.
[0024] A plane defined by at least one of the first roller set and
the second roller set may substantially horizontal. Alternatively,
a plane defined by at least one of the first roller set and the
second roller set is at a small angle to the horizontal. For
example, a plane defined by at least one of the first roller set
and the second roller set may be set at an angle of less than
20.degree. to a horizontal plane, or more particularly less than
10.degree. to a horizontal plane.
[0025] The first roller set can include at least one row of
parallel rollers. The second roller set can also include at least
one row of parallel rollers. The moving element can include a
manual mechanism. Alternatively, the moving element can include a
powered mechanism. At least one of the first roller set and the
second roller set can include a powered element. This powered
element may be controlled by a control system.
[0026] Another aspect of the invention can include a system for the
bi-directional transport of construction materials for use in a
material transport system. This system can include a plurality of
transport elements, wherein each of the plurality of transport
elements includes a table, a first roller set mounted to the table
and configured to support the construction materials on the table,
a second roller set mounted to the table, wherein the second roller
set is movable between a first position below a plane defined by
the first roller set and a second position above the plane defined
by the first roller set, and a moving element for moving the second
roller set between the first position and the second position,
wherein raising the second roller set to the second position allows
the second roller set to support the construction materials on the
table.
[0027] In one embodiment, the plurality of transport elements are
arranged in a grid, such as a rectangular or square grid. For
example, the plurality of transport elements may be arranged with
between one and three transport elements in one axis of the grid
and between one and ten transport elements in another axis of the
grid, resulting in a grid of up to thirty transport elements. In
one embodiment, the transport elements may have a surface area of
up to 24 ft by 24 ft. In an alternative embodiment, the transport
elements may have a smaller or larger surface area, as required.
The upper surface of the transport element may be set at any
appropriate height above the ground.
[0028] In one embodiment, the system can further include a space
between each neighboring transport element. The space may be sized
to enable passage of a person between the plurality of transport
elements. This can allow a user to move between tables in the
system to gain easy access to any portion of the construction
material being transported. The plurality of transport elements can
be configured to support the construction materials as they are
moved between tables. The construction materials may include
completed or partially completed building panels or parts thereof.
Alternatively, the construction materials may include boxes of
construction equipment or parts, machining equipment, or any other
large element that can be moved from one area of a manufacturing
facility to another.
[0029] Another aspect of the invention can include a method of
pinning a metal frame building panel for use in building
construction. This method can include the steps of positioning
components of a building panel in a predetermined arrangement for
pinning, holding the positioned components in position for pinning,
locating pin holes in the positioned components, positioning an
automated pinning system at a set starting position with respect to
the located pin holes, and inserting pins into the located pin
holes using the automated pinning system, thereby pinning the
components together to form a metal frame building panel.
[0030] In one embodiment, the locating step can include drilling
pin holes in the positioned components using a drill system. The
drill system can include a manually positionable drill.
Alternatively, or in addition, the drill system can include an
automatically positionable drill. The drill system may be adapted
to automatically create pin holes according to a predetermined
pattern.
[0031] In one embodiment, the locating step can include aligning
pre-drilled holes in the components. The automated pinning system
may be adapted to insert pins according to a predetermined pattern
corresponding with the locations of the pin holes in the positioned
components. The predetermined pattern may be stored by a control
system controlling the automated pinning system. The predetermined
pattern may be associated with a panel identifier attached to one
or more component of the panel. This panel identifier may include
panel information, panel material information, individual panel
assembly information, structure assembly information, job number
information, user information, and structure design information.
The panel identifier may include a barcode that may be read by a
barcode reader associated with the control system.
[0032] In one embodiment, the components may be held in position on
a framing table. In one embodiment, the automated pinning system,
and/or the control system, may be coupled to the framing table.
[0033] Another aspect of the invention can include an apparatus for
transporting a panel for use in metal frame building construction.
This apparatus may include a first track, a support member movably
coupled to the first track, at least two support arms coupled to
the support member, and a lifting member coupled to a distal end of
each of the at least two support arms, wherein each lifting member
is configured to engage an edge of a panel, and wherein the at
least two support arms are moveable with respect to each other such
that the lifting members can lift and support the panel in a
substantially horizontal orientation.
[0034] In one embodiment, the first track may be moveably coupled
to at least one second track. A longitudinal axis of the at least
one second track may be substantially perpendicular to a
longitudinal axis of the first track. In one embodiment, the
apparatus can include two second tracks. The two second tracks may
support the first track at its distal ends.
[0035] In one embodiment, the apparatus can include two support
arms. A means of moving the at least two support arms with respect
to each other can include a manual mechanism. Alternatively, a
means of moving the at least two support arms with respect to each
other can include a powered mechanism. The apparatus can further
include a control system. The control system may control the
movement of the at least two support arms. The control system may
further control the movement of the support member. The control
system may control the movement of the first track with respect to
the at least one second track.
[0036] In one embodiment, each lifting member may be configured to
engage the edge of the panel from below. As a result, the panel is
only supported from below, with a minimal force applied to the
edges of the panel. This may limit any damage to the panel during
transport. A small force may be applied to the edges of the panel
by the support arms to assist in stabilizing the panel.
[0037] In one embodiment, the first track and the at least one
second track may be configured to enable a panel to be transported
to any point within a plane defined by a limit of travel of the
support member and the first track. The at least one second track
may coupled to a roof of a building. Alternatively, or in addition,
the at least one second track may be supported by a plurality of
pillars attached to a floor and/or wall of a building.
[0038] A further aspect of the invention can include a method for
designing an enclosure using prefabricated panels. The method can
include the steps of receiving a design for a structure, creating a
model of the structure including prefabricated cold form steel
panels in response to the design, and generating, in response to
the model, structural specifications for the prefabricated
panels.
[0039] In one embodiment, the method can further include the step
of generating, in response to the structural specifications, a
parts list for the prefabricated panels. The method can also
further include the steps of manufacturing the prefabricated panels
in accordance with the structural specifications and collecting the
prefabricated panels and other parts for delivery. The collecting
step can include organizing the panels in a specific order in
accordance with the structural specifications to facilitate the
ease and speed of assembly upon delivery to a construction
site.
[0040] In one embodiment, the method can further include the steps
of delivering the panels to a construction site and assembling the
panels into a structure in accordance with the structural
specifications. The prefabricated panels can be selected from a
predetermined list of panel sizes and shapes. The prefabricated
panels may be of any size and shape to fit the design for the
structure. The structural specifications can include at least one
of panel information, panel material information, individual panel
assembly information, structure assembly information, job number
information, user information, and structure design information. In
one embodiment, the model of the structure may be created by a
computer-aided design tool. The computer-aided design tool can
include a database of acceptable panel configurations.
[0041] Another aspect of the invention can include a computer-aided
design (CAD) tool for designing a structure using prefabricated
panels. This tool can include an input function for receiving a
design for a structure, a modeling function for generating a model
of the structure based on the received design information, a
database of cold form steel panel configurations, a panel
application function adapted to fit appropriate panels to the
generated model, and an output function for generating structural
specifications for the required structural panels. The
specifications can include specifications for manufacturing and
assembling cold form steel parts into panels.
[0042] Another aspect of the invention can include a manufacturing
system for manufacturing a steel structure. The manufacturing
system can include a computer-aided design system for creating a
model of a building structure to be manufactured using cold form
steel panels and a manufacturing enterprise management system for
managing manufacture of each of the panels according to the
specifications and the fabrication drawings.
[0043] In one embodiment, the manufacturing enterprise system
generates specifications for panels, bills of materials for panels,
panel fabrication drawings, and panel installation drawings. The
system can further include a material optimizer for cutting
material and forming the metal into a part of a panel according to
the specifications and a material handling system including a tray,
conveyor, and rails for collecting parts, including parts formed by
the material optimizer, for assembly as described in the
fabrication drawings. The system can further include a pre-fastener
for fastening parts into a subassembly as described in the
fabrication drawings, a framing table for assembling parts and/or
subassemblies into a panel as described in the fabrication
drawings, and a sheathing table for applying a coating or covering
to the panel as described in the fabrication drawings. In one
embodiment, the system can further include an overhead gantry
system including a crane and a grabbing device for holding an
assembled panel and collecting panels for delivery.
[0044] One aspect of the invention can include a process for
managing the assembly of a panel for use in steel frame building
construction. This process may include receiving structure design
information from a computer aided design tool, providing
information for the selection of components for the panel from a
panel library, providing assembly instructions for the panel, and
tracking the location and stage of construction of the panel
through a manufacturing process.
[0045] In one embodiment, at least one of the component selection
information and panel assembly instructions is generated in a
printable format. The process can further include providing
information labels associated with at least one component of the
panel. The information labels can include construction information.
The construction information can include at least one of part
number information, assembly information, tracking information, job
number information, bar code information, panel information,
geometrical information, user information, and combinations
thereof.
[0046] In one embodiment, the tracking step can include entering
construction information into an information technology system. The
information technology system can include a plurality of user
interface terminals. The plurality of user interface terminals may
be associated with a plurality of workstations on an assembly line.
The information technology system can provide further construction
information to a user in response to the entering of construction
information into a user interface terminal. The plurality of user
interface terminals can include at least one of a barcode reader, a
touch sensitive screen, a computer terminal, a printer, and
combinations thereof.
[0047] Another aspect of the invention can include a kit for
manufacturing a habitable enclosure using prefabricated panels. The
kit can include a plurality of prefabricated metal panels, at least
one stabilizing element to releasably hold the plurality of
prefabricated panels in a predetermined manner during
transportation, and assembly instructions for assembly of the
plurality of panels into the habitable enclosure, wherein the
plurality of prefabricated metal panels are organized in accordance
with the assembly instructions during transportation in order to
facilitate ease and speed of construction.
[0048] In one embodiment, the plurality of prefabricated metal
panels can include a plurality of predetermined sizes and shapes.
Each of the plurality of prefabricated metal panels can further
include panel information attached thereon. The panel information
can include at least one of assembly information, manufacturing
site information, time information, user information, job number
information, bar code information, safety information, geometrical
information, and combinations thereof. The panel information may be
marked directly onto each individual prefabricated metal panel.
Alternatively, or in addition, the panel information may be marked
on a label affixed to each individual prefabricated metal
panel.
[0049] In one embodiment, the plurality of prefabricated metal
panels may be organized according to the order of use of the panels
during construction. The plurality of prefabricated metal panels
may be assembled into a plurality of bundles for transportation.
This allows the kit to be transported on a number of transport
vehicles, and/or be transported in stages. The plurality of bundles
can each include a stabilizing element. The kit can further include
at least one protective element. The protective element may be
configured to protect the plurality of prefabricated metal panels
from damage during transportation.
[0050] In one embodiment, The kit can further include a supporting
element. The supporting element may be configured to support the
kit during lifting and transporting. The supporting element may be
configured to enable lifting of the kit by at least one of a crane
and a forklift truck.
[0051] Another aspect of the invention can include a process for
manufacturing components for assembly into a metal frame panel for
use in metal frame building construction. The process can include
receiving panel design information for at least one component of a
metal frame panel from a computer aided design tool, sending the
component information for the at least one component to a metal
roll handler, and manufacturing at least one component of the metal
frame panel in accordance with the component information using the
metal roll handler.
[0052] In one embodiment, the process can further include marking
construction and assembly information onto the at least one
manufactured component for use in metal frame panel assembly. The
individual component information can include rolling and cutting
information. The rolling and cutting information can include at
least one of a length, a width, a thickness, a material, a cut
angle, a bend angle, a bend location, a cut location, and
combinations thereof.
[0053] In one embodiment, the metal roll handler can include a
cutting tool and a bending tool. The metal roll handler can further
include a metal roll holder and a feeding element for feeding an
unwound portion of a metal roll into at least one of the cutting
tool and bending tool. The panel design information can include
information for a plurality of components of a single metal frame
panel. In one embodiment, the process can further include grouping
the plurality of manufactured components for panel assembly.
[0054] Another aspect of the invention can include a method of
manufacturing a metal frame building panel for use in building
construction. The method can include the steps of selecting
components for an individual building panel and placing the
components on a material transport system. The method can further
include the steps of transporting the components on the material
transport system to a framing table, assembling the components into
an assembled panel on the framing table, and removing the assembled
panel from framing table.
[0055] In one embodiment, the method can further include the steps
of placing the assembled panel onto at least one bi-directional
roller table, transporting the assembled panel on the at least one
bi-directional roller table to at least one post-assembly work
station, and performing post-assembly work on the assembled panel
to complete the panel.
[0056] In one embodiment, the one or more post-assembly work
station can include at least one of a welding station, a sheeting
table, a painting station, an insulation insertion station, and
combinations thereof. The method can further include the steps of
lifting the completed panel using an overhead gantry and moving the
completed panel to a storage area using the overhead gantry. The
material transport system can include at least one work
station.
[0057] In one embodiment, the at least one work station can include
at least one of a tray loading station, an inventory check station,
a test station, a monitoring station, a pre-weld station, a
sub-assembly station, an assembly station, a post-weld station, and
a sheeting station. The assembling step can include positioning the
components in a predetermined arrangement and pinning the
components together to form the assembled panel. At least one of
the steps may be at least partially automated. For example, the
pinning step may be at least partially automated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] FIG. 1 is a schematic perspective view of a manufacturing
facility, in accordance with one embodiment of the invention;
[0059] FIG. 2 is a schematic plan view of a material optimizer, in
accordance with one embodiment of the invention;
[0060] FIG. 3A is a schematic plan view of a material transport and
assembly system, in accordance with one embodiment of the
invention;
[0061] FIG. 3B is a schematic plan view of a material handler, in
accordance with one embodiment of the invention;
[0062] FIG. 4A is a schematic side view of a start elevator for a
material handler in a lowered configuration, in accordance with one
embodiment of the invention;
[0063] FIG. 4B is a schematic side view of the start elevator of
FIG. 4A in a raised configuration;
[0064] FIG. 5A is a schematic side view of a framing table, in
accordance with one embodiment of the invention;
[0065] FIG. 5B is a schematic end view of the framing table of FIG.
5A;
[0066] FIG. 5C is a schematic perspective view of the framing table
of FIG. 5A with an attached fastening element;
[0067] FIG. 5D is a schematic perspective view of the framing table
of FIG. 5A supporting a panel;
[0068] FIG. 5E is a schematic side view of another framing table,
in accordance with one embodiment of the invention;
[0069] FIG. 5F is a schematic plan view of another framing table,
in accordance with one embodiment of the invention;
[0070] FIG. 6A is a schematic end view of a bi-directional roller
table with the second roller set in a lowered configuration, in
accordance with one embodiment of the invention;
[0071] FIG. 6B is a schematic side view of the bi-directional
roller table of FIG. 6A with the second roller set in a lowered
configuration;
[0072] FIG. 6C is a schematic end view of the bi-directional roller
table of FIG. 6A with the second roller set in a raised
configuration;
[0073] FIG. 6D is a schematic side view of the bi-directional
roller table of FIG. 6A with the second roller set in a raised
configuration;
[0074] FIG. 6E is a schematic perspective view of the
bi-directional roller table of FIG. 6A with the second roller set
in a lowered configuration;
[0075] FIG. 6F is a schematic perspective view of a plurality of
bi-directional roller tables, in accordance with one embodiment of
the invention;
[0076] FIG. 7A is a schematic end view of an overhead gantry, in
accordance with one embodiment of the invention;
[0077] FIG. 7B is a schematic side view of the overhead gantry of
FIG. 7A;
[0078] FIG. 7C is a schematic side view of an overhead crane, in
accordance with one embodiment of the invention;
[0079] FIG. 7D is a schematic side view of the crane arm of FIG.
7C;
[0080] FIG. 8 is a flowchart of a method, in accordance with one
embodiment of the invention;
[0081] FIG. 9 is a block diagram of the components of an embodiment
of the invention;
[0082] FIG. 10 is a block diagram of a design system, in accordance
with one embodiment of the invention;
[0083] FIG. 11 is an exemplary display of a parametric model of a
structure, in accordance with one embodiment of the invention;
[0084] FIG. 12 is another exemplary display of a parametric
model;
[0085] FIG. 13 is an exemplary panel material list, in accordance
with one embodiment of the invention;
[0086] FIG. 14 is an exemplary panel assembly drawing, in
accordance with one embodiment of the invention;
[0087] FIG. 15 is an exemplary panel assembly drawing, in
accordance with one embodiment of the invention;
[0088] FIG. 16 is an exemplary panel assembly drawing, in
accordance with one embodiment of the invention;
[0089] FIG. 17 is a portion of an exemplary panel assembly drawing,
in accordance with one embodiment of the invention;
[0090] FIG. 18 is exemplary data export information, in accordance
with one embodiment of the invention;
[0091] FIG. 19 is an exemplary bar code label, in accordance with
one embodiment of the invention; and
[0092] FIG. 20 is a flowchart of a method, in accordance with one
embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0093] One embodiment of the invention can include a material
transport system for use in manufacturing panels for building
construction, such as in buildings constructed from steel frame or
other appropriate building materials, including, but not limited
to, aluminum or other metals, wood, plastics, composite materials,
or combinations thereof. The material transport system can include
a rail system allowing an empty tray to be loaded with appropriate
materials for a specific panel. These trays can then be used to
transport the panel materials to different stations on a
manufacturing production line. Stations on the production line can
include, but are not limited to, pre-welding, construction (at
"framing tables"), post-welding, and sheeting stations. The panels
can be moved between one or more of the stations on roller systems.
The trays for carrying the original materials can be returned to
the starting location, either automatically or manually, after
delivery of the materials to the framing tables.
[0094] An example manufacturing facility 100 can be seen in FIG. 1.
This manufacturing facility 100 includes a material optimizer 120
and steel coils 110 used to form and cut steel into material that
can be assembled into panels. The manufacturing facility 100
further includes a material handler 130, one or more preprocessing
stations 140, a number of framing tables 150, a number of
bi-directional transport tables 160, one or more post-processing
stations 170, an overhead gantry system 180, and a stacking system
190.
[0095] A manufacturing facility 100 can, according to one
embodiment of the invention, use steel coils 110 as the raw
material used to form the panels. Each panel that is fabricated may
be unique in terms of size, connections, number of components, and
so on. As such, the processes described herein allow for the
efficient fabrication of custom designed panels, which ultimately
results in the efficient fabrication of a custom-design
building.
[0096] The steel coils are provided as input to a material
optimizer. The material optimizer forms and cuts steel into
material that can be assembled into panels. In one embodiment, the
material optimizer receives data from a manufacturing management
application that may include design and fabrication information for
the components to be included in each individual panel being
manufactured. For example, a bill of materials for each panel may
include information about the components required for the panel.
The material optimizer can use this information to de-coil, cut,
and/or shape each flat steel panel component. For example, if a
number of studs of a predetermined type are needed for a specific
panel, the material optimizer 120 may manufacture those studs for
assembly into the panel.
[0097] An example of a material optimizer is shown in FIG. 2. In
this embodiment, the material optimizer 120 starts with large steel
coils 110 that can be passed through a de-coiler 220 for
straightening. The straightened piece of steel is then cut to
length and picked up by an overhead gantry system 225 to be fed
into a roll-former 230. The steel cutter may be integrated into the
roll-former 230, or be a separate component. The roll-former 230
can be adjusted, either automatically or manually, to form a piece
of steel into the required shape, for example, to form a stud or a
track. The roll-former 230 may include one or more roll-dies that
incrementally form the steel and can create various shapes and
sizes. From the roll former 230, the component may be placed on a
picking area 240 for placement on a material handler for use in
panel construction.
[0098] The de-coiler 220, cutter, overhead gantry system 225 and
roll former 230 may, in one embodiment, be formed into an
integrated system. This system can be controlled by a control
system that receives data from a management system or other
appropriate panel and element selection system. This allows for the
controlled production of the steel components that are used to
fabricate a panel. The integration of these components can provide
significant benefits in this application, in that it becomes
possible to efficiently manufacture individual panel components
from raw materials.
[0099] In the embodiment of FIG. 2 the material optimizer 120
covers a total floor space of approximately 100 ft by 40 ft. In
alternative embodiments, larger or smaller material optimizer
systems may be used, depending upon the requirements of the
manufacturing facility 100, with each component of the material
optimizer sized accordingly. In addition, the individual components
may take up more or less floor space, again as required.
[0100] In an alternative embodiment, the material optimizer can
include one or more folding elements to fold the cold form steel
into the required shape, such as, for example, a stud, track,
I-beam, or other appropriate shape for use in panel construction.
These folding elements may, in one embodiment include hydraulic
powered mechanical arms or panels configured to bend a portion of a
cold form steel roll at a prescribed angle. A clamping mechanism
may be utilized to hold the cold formed steel roll section in place
during the bending process. In an alternative embodiment, an
electric motor driven, or otherwise powered bending mechanism may
be utilized. In further embodiments, any appropriate combination of
crimping elements, cutting elements, bending elements, and/or
rolling elements may be integrated into the material optimizer to
produce the necessary parts for panel construction.
[0101] Once each panel component has been cut and formed by a
material optimizer, the fabrication process of building custom
panels in an efficient manner can continue. In one embodiment of
the invention, each component for a specific panel that is
manufactured by the material optimizer is placed in a picking area,
prior to loading onto a material handler. The material handler then
transports the selected components to individual process and
fabrication stages in an efficient, flexible manner.
[0102] One embodiment of a material transport and assembly system
including a material handler is shown in FIG. 3A. The material
handler 130 may allow the tray to move to one or more workstations.
After, or without, preprocessing at these workstations, the tray
may be moved to a framing table 150 for assembly. In this
embodiment, the material handler 130 can include a start elevator
310, one or more trays 320, and a conveyor and/or rail system 330
for moving these trays. The trays 310 are designed to hold long
pieces of cold-formed steel components, such as those formed by a
material optimizer. In one embodiment, a tray 310 is made of steel
and includes roller-wheels that lock into a rail system 330 that
moves the trays into certain functional areas. Other metals,
plastics, woods, composites, or combinations of these materials may
also be used for the trays. Due to the tray design and the roller
wheels being incorporated into the system, the tray can be moved
from one work station 340 to another with very little effort and
with a significant level of flexibility. In particular, by allowing
different patterns of movement, the conveyor enables variable
movement to each work area, which allows the production line to be
flexible. In an alternative embodiment, the rail system itself has
rollers, or other rolling or sliding elements, incorporated
therein, therefore eliminating the need for rollers on the
trays.
[0103] In one embodiment, the work station 340, or work stations,
can include at least one of a tray loading station, an inventory
check station, a storage station, a test station, a monitoring
station, a pre-weld station, a sub-assembly station, an assembly
station, a post-weld station, a painting station, and a sheeting
station. The material handler 130 may include any number and
combination of these stations, depending upon the specific
requirements of the material transport system 100. The rail system
330 can be adapted to provide tray paths allowing the tray 320 to
pass through any appropriate combination of stations.
[0104] One example work station may include a stitch welder system.
This stitch welder may be used to pre-weld studs, and/or other
panel components, prior to final assembly. In one embodiment, the
stitch welder may include a stationary welding robot specifically
designed to pre-weld panel components of varying size and shape. In
operation, panel components that require pre-welding may be placed
directly within the welding system. Alternatively, panel components
may be placed on a conveyor belt, or other transport element
configured to transport panel components, which transports the
panel component or components through the welding system. Once the
panel components have been welded, they can be placed back on the
rail system, either manually or automatically, for transport to the
next work station and/or framing table. In one example embodiment,
the welding system may include a spray painting unit to paint the
panel components prior to being returned to the material
handler.
[0105] The rail system may include any number of starting locations
and any number of end locations. In the embodiment of FIG. 3A, the
rail system 330 includes one start location, situated at the
position of the start elevator 310, and four end locations 350,
leading to the framing tables 150. As shown, the framing tables 150
then lead on to bi-directional transport tables 160,
post-processing stations 170, an overhead gantry system 180, and
any further elements of the material transport system 100 that may
be required.
[0106] In one embodiment of the invention the tray 320 may be moved
manually along the rail system 330. This movement may be gravity
assisted or be gravity neutral, depending on whether the rail
system 330 is flat or pitched at a slight angle. In one example
embodiment of the invention, different portions of the rail system
may be either flat or pitched at an angle, allowing for some parts
of the rail system 330 to be gravity assisted while other parts are
gravity neutral. In an alternative embodiment, a means of
automatically moving the tray 320 along the rail system 330 may be
employed.
[0107] Another example material handler, including example
dimensions for each portion of the system, can be seen in FIG. 3B.
In this embodiment, a tray 320 can have components that are
manufactured by the material optimizer, as well as any
instructions, documentation, and additional components that might
be needed that are not available at the individual workstations.
The tray can travel on the conveyor section 360 to the junction
365. At junction 365, the tray may go in either direction, so as to
be placed at pre-processing work stations 370 or 375, or go
straight through conveyor section 380 towards junction 385.
[0108] At work station 370, for example, there may be a robotic
welder, described further below. At work station 375 there may be
another robotic pre-welder, or another pre-processing workstation.
After stopping at the pre-processing workstations for pre-assembly
processing, or after passing by such processing, the tray 320 may
travel down conveyor section 390 to junction 395, at which point
the tray can be directed to any one of the framing tables 150.
[0109] In such a custom manufacturing environment, there is no
pre-determined length of time for any particular function or step
within the manufacturing process. Often, each panel is unique,
making the amount of time required for each function, or at each
work station, variable. The conveyor system enables this
variability because trays can be moved in all directions into an
open work cell without lifting.
[0110] Different work stations may have different functions and
equipment associated therewith, depending upon the requirements for
each panel being manufactured. In one example embodiment, a
workstation may include a pre-fastening station. Pre-fastening,
such as welding, can be used, for example, to form a sub-assembly
required for a panel. A pre-welder may be a robotic based welder
that welds galvanized cold-formed steel components together to
create sub components to be used in the panel fabrication process.
The pre-welder may weld galvanized steel in an automated manner,
and have the capability to weld different components at unique weld
points.
[0111] In one embodiment, a pre-welder may have a robotic welding
arm. Information from a manufacturing management system may be
provided to the robotic welder so that it knows what operations to
perform. For example, a bar code associated with the components may
be scanned, and the robotic welder may receive information based on
the bar code, that provides the specific weld point information and
the type of welding required for that subcomponent. This may be,
for example, information about the welding that is generated by the
design system and exported to the management system for access by
the welder. The information may be provided in response to a
request that includes the bar code. The steel is then provided to
the welder, and the robotic arm may weld the metal components
together. The welded components can then be placed back on the
tray. Alternatively, the pre-fastening may be carried out on the
tray itself.
[0112] In one specific implementation, the welding station can
include a feeder element for feeding components through the
pre-fastening workstation and a robotic arm. The robotic arm can
include a weld tip that enables it to weld cold-formed galvanized
steel, as well as a galvanized spray painter. The robotic welding
arm has a presetting control system that identifies where the weld
is specified to be and is flexible so that it can weld according to
any specification. The robotic arm has this flexibility and may
weld at different locations for each piece of steel that enters
into the arm.
[0113] In one embodiment, a tray 320 can be moved from the start of
the material handler 130 through the one or more fabrication work
stations 340 to the end of the material handler 130, and then
return back to the beginning of the process without the need to
lift any of the trays 320. Once all the components on the trays 320
have been through the one or more work stations 340 specified for
that component, the tray 320 may then be sent back to the beginning
of the process either manually or automatically, after which steel
components for the next panel can be placed on the tray. In one
implementation, the conveyor enables the tray 320 to lower at the
end of the process and travel underneath the conveyor to the
beginning of the fabrication process on a return leg.
[0114] In one embodiment, the material handler 130 can also include
a return leg adapted to return a tray to the starting location upon
transport of the panel materials to the one or more framing tables.
The return leg can include a track located either below or above
the rail system. This return leg may be automatic, manual, and/or
gravity assisted, as required. The return leg track may return the
tray 320 to a start elevator 310, which can place the tray 320 back
onto the start of the rail system 330 for reuse.
[0115] An example of a start elevator 310 can be seen in FIGS. 4A
and 4B. The start elevator 310 can be lowered to a lower level to
receive empty trays from a return leg 410 of the material handler
130, and then be raised to the upper level rail system 420 to allow
the tray 320 to be loaded and sent down the production line.
[0116] The start elevator 310 positioned at the lower level is
shown in FIG. 4A. A tray holder 430 is positioned level with the
return leg 410 such that the tray 320 may slide off of the return
leg 410 and onto the tray holder 430 in the direction shown 440. As
discussed above, this movement of the tray may be manual, gravity
assisted, or automatic. The tray holder 430 is supported by a
hydraulic jack 450 and a frame 460. The hydraulic jack 450 is
controlled by a control element 470, which may in turn be
controlled by a material handler control system that oversees
multiple functions of the process. Alternatively, the control
element 470 may be a button or other appropriate user interface
element allowing raising or lowering of the tray holder 430 upon
actuation by a user.
[0117] Once a tray 320 has been placed on the tray holder 430, the
hydraulic jack 450 can be activated to lift the tray holder 430 up
to the level of the rail system 420, as shown in FIG. 4B. The tray
320 can then be loaded with components for the next panel 480
before being directed down the rail system 420 towards the required
workstations in the direction shown 490.
[0118] In alternative embodiments, other lifting and lowering
equipment may be used, including, but not limited to, a pulley
system, a winching system, a scissor lift system, a crane-type
system, a screw system, or other appropriate lifting apparatus.
This lifting apparatus may be electrically and/or hydraulically
powered, or may be manually operated.
[0119] Once the components have been pre-processed and/or moved to
the end of the material handler 130, they can be placed on a
framing table 150 for assembly. Framing tables 150 are designed to
enable the efficient fabrication of a panel. For example, in one
embodiment, each framing table 150 enables a fabricator to
efficiently lay out a panel and all of its components, fabricate
it, fasten it, weld it and build it with minimal labor.
[0120] The framing table can also be integrated with enterprise
management software, so that every panel that arrives at the table
has a unique identifier, such as a barcode, with specific assembly
instructions coded into the identifier. Based on this
identification information, the panel may be identified by
equipment at the table to determine layouts, fastening patterns,
number of components and fabrication time required for this panel,
as well as other specific elements for the panel.
[0121] The framing table has many elements that assist with
fabrication. Examples of these elements include the ability to
fasten panels from the top and bottom, compression capability,
robotic movement of fastening tools, and automated marking and
layout information.
[0122] Compression capability may include one or more compression
elements configured to provide a compressive force to at least a
portion of the panel components, and/or assembled panel, to assist
in the assembly and fixing of the assembled panel. For example, a
compressive force may be applied to portions of the assembled panel
to ensure a close fit of the components prior to and/or during
pinning, welding, gluing, or fixation of the panel through other
appropriate means. The framing table may include separate
compression elements, such as, but not limited to, hydraulic
elements, motorized elements, air compression elements or manually
operated mechanical elements configured to provide a compressive
force. Alternatively, the framing table may provide a compressive
force itself through the movement of one or more of the panel
supports within the tracks. For example, once the panel components
have been correctly positioned for assembly, the tracks may be used
to move the panel supports slightly closer together such that the
side bars on the panel supports compress the panel components into
a tight fitting arrangement ready for fixation.
[0123] An example framing table 150, in accordance with one
embodiment of the invention, can be seen in FIGS. 5A-5E. The
framing table 150 includes two panel supports 510. These panel
supports 510 include a support structure 520, a transport element
530 mounted to an upper portion of each support structure 520 and
configured to enable slideable movement thereon, and a side bar 540
mounted to an upper portion of the support structure 520. The side
bars 540 are configured to hold the building panel in position
during assembly. The panel supports 510 are mounted on a pair of
tracks 550 to enable relative movement between the two panel
supports 510, thus allowing the framing table to be configured to
hold panels of differing dimensions.
[0124] In other embodiments, only one of the panel supports 510
need be mounted on a track, such that it can move relative to a
stationary second panel support 510. In still other embodiments, a
greater number of panel supports 510, and or side bars 540 may be
used to releasably hold the panel in place during assembly.
[0125] The framing table 150 can also include a control system,
allowing for the automated control of the panel supports 510 to
support and hold the specific panel being constructed. This control
system may operate in response to an identifier associated with one
or more of the panel components (e.g. a bar code, and RFID tag, and
so forth), resulting in the framing table 150 being configured for
the panel being constructed from the components associated with the
identifier. For example, the panel control system may respond to
information such as, but not limited to, a bar code scan, an RFID
signal, a request inputted by a user, a selection from a menu of
stored information, or other information about the panel, and
configure the framing table 150 in response.
[0126] In one embodiment, the framing table 150 is configured to
support a building panel as large as 24 ft by 24 ft, and as small
as 3 ft by 3 ft. In alternative embodiments, the framing table 150
is configured to support ranges of building panel dimensions of any
appropriate size and shape.
[0127] The panel supports 510 can be supported by the same track
550 or by different tracks. The side bars 540 are configured to
provide a compression force on the building panel during assembly.
This compressive force may be applied, for example, by moving the
panel supports 510 slightly closer together on the tracks 550 after
the components of the panel have been correctly positioned. This
movement may be carried out automatically in response to an input
to the control system, or be carried out manually.
[0128] The framing table 150 can include at least one hydraulic
lift 560, configured to enable vertical movement of an upper
section 570 of at least one of the panel supports 510. The
hydraulic lift 560 can be configured to enable simultaneous
vertical movement of the upper sections 570 of the panel supports
510, or be configured to work independently. By allowing the upper
sections 570 of the panel supports 510 to be lifted and lowered,
access to the panel from below and/or above can be easily
facilitated, allowing for easy access to all portions of the panel
during assembly.
[0129] The framing table 150 can include at least one fastening
element 580, such as a screw gun. The screw gun, or guns, may be
manually operated or automatically operated in response to a signal
from the control system. The fastening element 580 can be
releasably mounted to the framing table 150, be permanently mounted
to the framing table 150, or be uncoupled from the framing table
150. In one embodiment, the screw gun can be attached to a robotic
arm coupled to a panel support 510, allowing for the automatic
insertion of screws or other fixing elements, such as, but not
limited to rivets, nails, and clamps, in response to a control
signal from the control system.
[0130] In an alternative embodiment, the framing table 150 may
include two or more fastening dollies that have screw guns
incorporated in both the top and bottom of the dollies. These
dollies can be configured to move along the vertical side of the
panel. The dollies can have button controls which enable them to
fasten components of the panel, such as, but not limited to, top
and bottom steel studs and/or steel tracks. The dollies can be
moved easily by the operator to any location that requires
fastening to occur. Alternatively, the dollies may be automatically
moved in response to a control input from the control system.
[0131] The dollies may also contain a welding unit. For example, an
overhead welding arm can be used allow welding of components, if
required for structural strength or other reasons. In one
embodiment, the weld dollies can by positioned on a support
structure attached to, or separate from, the framing table,
allowing for movement of the welding unit in one or more axis
around the table, thus allowing welding of any portion of the
assembled panel.
[0132] In one embodiment, the table provides markings with a laser
or lighting system for placement of parts for fastening. Dollies
can then sense these marking locations and used them to weld
components, and/or insert fastening elements, where specified by a
control and management system.
[0133] In use, a metal frame building panel can be constructed by
first positioning components of a building panel in a predetermined
arrangement on the framing table 150. Once the framing table has
been engaged to hold the positioned components in position, the
components can be pinned together, or otherwise connected. This can
be done, in one embodiment of the invention, by locating and
aligning predrilled pin holes in the positioned components,
positioning an automated pinning system at a set starting position
with respect to the located pin holes, and inserting pins and/or
screws into the located pin holes using the automated pinning
system, thereby pinning the components together to form a metal
frame building panel. In an alternative embodiment, self-tapping
screws may be used instead of, or in addition to, the pins inserted
into predrilled holes. Using self-tapping screws alleviates the
need to have aligned pin holes in the panel components prior to
fixing.
[0134] In one embodiment, male and female tabs, or other
appropriate mating elements, may be incorporated into some or all
of the panel components to ensure that they are correctly
positioned and aligned upon placement on the framing table 150. The
addition of male/female mating elements on components of the panel
may be advantageous, for example, when an automatic alignment
mechanism is incorporated into the framing table to align the
components prior to fixation of the panel.
[0135] In one embodiment, one or more functions of the framing
table and associated methods may be automated. For example, an
automatic alignment mechanism may be incorporated into the framing
table 150 to accurately align at least a portion of the panel
components within the framing table 150 after they have been placed
in position. One example embodiment of the framing table 150 may
include a fully automated fastening system. With this fully
automated system, as soon as the panel has been assembled ready for
fastening an operator can simply initiate a fastening program
associated with a framing table control system, for example by
pushing an appropriate button on the control system. Upon
initiation, the control system can control an automated pinning,
welding, gluing, and/or screwing system, to automatically fasten
the panel.
[0136] The pin holes may first be drilled in the positioned
components using a drill system at the framing table 150, or be
drilled at a pre-processing work station prior to setting the
components in the framing table 150.
[0137] The drill system can include a manually positionable drill
or an automatically positionable drill. The drill system may be
adapted to automatically create pin holes according to a
predetermined pattern. This predetermined pattern may be stored by
a control system controlling the automated pinning system. The
automated pinning system and/or drilling system may be coupled to
the framing table 150 or be separate from the framing table
150.
[0138] In one embodiment, the transport element 530 can include a
plurality of rollers, allowing the panel to be easily slid off of
the framing table 150 after assembly. These rollers may, in one
embodiment, be powered to allow the constructed panel to be
automatically rolled from the framing table 150 upon a signal from
the control system. Alternatively, the rollers may be free moving,
allowing the panel to simply be pushed from the framing table 150
by a user. In an alternative embodiment, the rollers may be raised
or lowered within the upper section 570 of the framing table 150
allowing the panel components to rest on a solid, non-rolling,
surface during construction, but allowing the constructed panel to
be rolled from the framing table 150 after construction is complete
by raising the rollers. A constructed panel 585 positioned on a
framing table 150 is shown in FIG. 5D.
[0139] Another example framing table is shown in FIG. 5E. In this
embodiment a framing table 150 is approximately 24 feet by 24 feet
in dimension and has many components, including two sides 590 to
each table that are variable such that they can move to any
location depending on the size of the panel. When components are
placed on the table, the sides can compress the components together
to prepare them for fastening and to ensure the materials will
withstand structural requirements. The framing table 150 also sits
on a hydraulic lift 560 or jack that allows the table to be raised
and lowered. This allows a worker to arrange the components and
fasten them together as needed.
[0140] A plan view of a further alternative embodiment of the
framing table can be seen in FIG. 5F. In this embodiment, the panel
supports 592 are supported by tracks 594 and runners 596, allowing
the panel supports 592 to be moved closer together or further apart
as required. A walkway 598 allows a user to easily walk between the
two panel supports 592 and associated tracks 594.
[0141] After assembly at the framing tables 150, the panels may be
rolled off of the framing table 150 and onto one or more
bi-directional roller tables 160. These tables allow ease of
movement of assembled panels in all four directions, thereby
enabling panels to move into free work areas efficiently and with
relatively little effort. In one embodiment, there are two sets of
rollers positioned at right angles to each other, allowing movement
in two axes. At least one set of the rollers can be raised and
lowered to engage or disengage the underside of the panel, box, or
other material being carried on the tables, depending on the
desired direction of panel movement. For example, when the rollers
are in a first position, as shown in FIGS. 6A, 6B and 6E, a panel
can move in a first direction, and when the rollers are in a second
position, as shown in FIGS. 6C and 6D, the panel can move in a
second direction.
[0142] A bi-directional roller table 160 for the transport of
construction materials for use in a material transport system can
include a first roller 610 set mounted to the table and configured
to support the construction materials on the table and a second
roller 620 set mounted to the table and also configured to support
the construction materials on the table. The second roller set 620
is movable between a first position below a plane defined by the
first roller set 610 and a second position above the plane defined
by the first roller set 610. The first roller set 610 is configured
to support the construction materials in a first direction of
travel, and the second roller set 620 is configured to support the
construction materials in a second direction of travel. The first
direction of travel is perpendicular to the second direction of
travel. The plane defined by the first roller set 610 is
substantially horizontal. In an alternative embodiment, at least a
portion of one or more sets of the rollers on the bi-directional
roller table 160 may be slightly angled, allowing for gravity
assisted movement of the panel, or other material being
transported, in a set direction.
[0143] The bi-directional roller table 160 can also include a
moving element for moving the second roller set 620 between the
first position and the second position, wherein raising the second
roller set 620 to the second position allows the second roller set
620 to support the construction materials on the table. As a
result, the panel, or other material supported by the table, can
move in one direction 630 on the first roller set 610 when the
second roller set 620 is lowered, and in a second direction 640
when the second roller set 620 is lowered, as shown in FIG. 6E.
[0144] The first roller set 610 includes at least one row of
parallel rollers. A larger number of rows, or longer and/or wider
rollers, may be used, depending upon the size and type of materials
being carried and the size and shape of the room in which the
bi-directional roller tables 160 are being located. The second
roller set can include at least one row of parallel rollers.
[0145] The moving element used to raise and lower the second roller
set 620 can include a manual mechanism and/or a powered mechanism.
For example, a motorized or hydraulic lifting mechanism may be
used, in one embodiment of the invention, with the motorized
mechanism controlled by a user input control, such as a switch or
button control. In an alternative embodiment, the control system
for the motorized lifting mechanism may be in communication with a
production management system controlling a plurality of functions
of the panel construction assembly process. A manual mechanism for
raising and lowering the second roller set 620 can include, but is
not limited to, a winding mechanism, a crank mechanism, a spring
mechanism, or combinations thereof.
[0146] In one embodiment of the invention, a plurality of
bi-directional roller tables 160 may be located together, with the
space between each table large enough for a user to walk in between
the tables, but small enough so that the panels do not fall into
the gaps when rolling from one table to the next. The lifting and
lowering mechanisms for each table may be controlled separately.
Alternatively, a portion of the tables, or all of the tables, may
be configured to raise and lower the second roller set 620
together. An example of multiple tables configured to work together
is shown in FIG. 6F.
[0147] Use of the bi-directional roller tables 160 enables movement
of the panels into any open post-processing work station or storage
area, further enabling a flexible and dynamic movement pattern. In
one example embodiment, the panel may be moved to a sheathing stage
170. The sheathing tables are designed for the application of
specific sheathing finishes (e.g., coatings or coverings) to be
placed on panels for completion. For example, the sheathing may
include insulation for wall panels, or may include painting or
other finish of that nature. Once panels are sheathed, they are
then ready to be piled and sent to the construction site for
installation.
[0148] Once a panel has been fully assembled and sheathed (if
required), it is ready to be moved from the assembly line to either
a storage area or a shipping area. This panel transport function
can, in one embodiment of the invention, be carried out by one or
more overhead gantry systems 180 located beyond the sheathing
tables and post-processing tables. This overhead gantry system 180
can lift the panels using a special "arm-like" device, which is
specially configured to lift panels that are relatively heavy but
manufactured of materials that may be damaged if not lifted
properly. In one embodiment, the overhead gantry system is
configured to lift these panels and stack them in a preset
configuration ready for fastening and shipping to a construction
site. An example overhead gantry system is shown in FIGS. 7A and
7B.
[0149] In one embodiment of the invention, the overhead gantry
system 180 includes a track 710, a support member 720 movably
coupled to the track 710 by a coupling member 715, and two support
arms 730 coupled to the support member. The support member may be
able to be raised or lowered from the coupling member 715. The
overhead gantry system 180 further includes a lifting member 740
coupled to a distal end of each of the support arms 730. Each
lifting member is configured to engage an edge of a panel 750. The
support arms 730 are moveable with respect to each other such that
the lifting members 740 can lift and support the panel 750 in a
substantially horizontal orientation.
[0150] The support arms 730 may be moved with respect to each other
by either a manual mechanism or a powered mechanism. A control
system may be used to power and control the movement of the support
arms 730 with respect to one another, and control the movement of
the coupling member 715 within the track 710. The control system
can further control the vertical movement of the support member
720.
[0151] The track 710 can be movably mounted on a second pair of
tracks 760, which may be structurally supported by support members
770, and/or be mounted to the structural supports of a building. As
a result, the panel may be lifted or lowered and moved in two
horizontal axes along the track 710 and the tracks 760. This allows
the panel 750 to be picked up from a given location, such as a
sheathing table, and delivered to any point within the range of the
track system.
[0152] In one embodiment, the overhead gantry may include a crane
element associated with the coupling member 715 to lift and lower
the panel when supported by the lifting members 740. This crane
element may involve a winching, winding, pulley, or other
appropriate lifting mechanism.
[0153] In an alternative embodiment, the overhead gantry may be
replaced by one or more crane systems. The crane system may be a
portable crane or be a crane system permanently mounted within a
manufacturing building.
[0154] An example of an overhead crane system is shown in FIGS. 7C
and 7D. In this embodiment the overhead crane system includes an
x/y access frame 780, with a crane 785 and grabbing device 790
which can lift panels and move them in any direction. The grabbing
device 790 can include a handset with controls which enable the
grabbing device 790 to move in any direction within the limits of
the x/y access frame 780. Referring to FIG. 7D, the grabbing device
790 may need to hold panels that weigh up to 1,500 lbs but yet are
delicate and can easily be damaged. As such, the grabbing device
790 must be configured to provide sufficient lifting and support
force to lift and hold the panels, but not produce any force on the
panel to damage it in any way. In an alternative embodiment, the
grabbing device may be a hook, a clasp, or any other appropriate
mechanical element for hooking to a panel or a support strap
attached to the panel.
[0155] In an alternative embodiment, a panel lifting element may be
incorporated into any of the described overhead gantry or crane
systems to enable panels of over 4,000 lbs to be supported and
transported safely. This panel lifting element may be configured to
lift and support a single panel, or lift a plurality of stacked
panels. As a result, the overhead gantry and crane systems can be
used to load completed panels and/or panel kits directly onto
transport vehicles
[0156] Another aspect of the invention can include information
technology systems and methods for the utilization and control of
the manufacturing systems described herein. These information
technology systems and methods may include, in certain embodiments,
systems for manufacturing components for assembly into a panel, the
creation of housing kits from panels manufactured within the
facility, methods of designing an enclosure using such panels,
and/or a computer aided design tool for designing a structure using
prefabricated panels.
[0157] Referring to FIG. 8, in one embodiment, a process for
manufacturing a structure may include some or all of the following
steps. The process may include receiving a design for a structure
(STEP 810). The design may be, for example, an architectural
design, and/or an engineering design. The design may be based on
another design, a previously developed design, or may be an
original or custom design. The design typically will specify such
items as the size and shape of the structure, and present some or
all of the desired architectural features.
[0158] The process may further include creating a model of the
structure in response to the design (STEP 812). The model,
typically, will be a virtual model created in a computer-aided
design software program, such that the model is a virtual
representation of the structure. Preferably, the model includes a
number of panels, each of which has a number of cold-formed steel
members that are assembled into one panel unit. Creation of the
model typically will involve the use of pre-designed panels, but
may involve the creation of some or all custom panels. Creating the
model may involve selecting panels that will be used to construct
the design such that the engineering and architectural requirements
for the structure will be met. In response to the panels that are
selected for the model, the design software may generate
specifications for the panels, bills of materials for panels, panel
fabrication drawings, and panel installation drawings (STEP
814).
[0159] The process may further include managing in a manufacturing
facility manufacture of panels selected in the model (STEP 816).
This may be performed as described herein, in a facility as
described above. This may be performed, for example, according to
the bill of materials and the fabrication drawings. This may be
performed for some, most, or all of the panels. For example, it may
be possible to manufacture some portion of the panels in another
facility, or on site, and the manufacture in the facility of some
or all of the panels may be complete, partially complete, or
incomplete. In one embodiment, all of the panels are manufactured
in a manufacturing facility, so that the work that needs to be
performed on site is primarily assembly. It should be understood
that, in general, more work done in a manufacturing facility will
result in less work that needs to be done on-site.
[0160] The process may further include collecting in the
manufacturing facility the panels for delivery to a construction
site for the structure (STEP 818). Other necessary parts may also
be assembled for delivery. In one embodiment, panels are collected
in the approximate order that they will be needed for assembly, to
make construction that much more efficient. In one embodiment, the
panels are collected in piles, so that they can be fastened
together and loaded onto a truck. In one embodiment, the panels are
collected in a manner that allows the panels to be moved, but not
damaged. In one embodiment, the piles are made such that the panels
to be used first are on the top, and the panels are in the pile in
the order that they will be needed for construction. In one
embodiment, manufacture of the panels in the manufacturing facility
is accomplished such that the assembled panels can be piled in
order.
[0161] The process may further include transporting the panels to a
construction site (STEP 820). Other parts may also be transported.
This may be accomplished by ground transport (e.g., truck(s)),
rail, air, or any other suitable transportation, although
typically, it will be accomplished by truck. The panels, stacked
and fastened as above, may be loaded onto a truck and driven to a
site, where they may be unloaded and unfastened for
construction.
[0162] The process may further include, at the construction site,
assembling the panels into a structure (STEP 822). This may be
accomplished in any suitable manner. In one embodiment,
construction drawings generated at the time of design will be used
to assemble the panels. In one embodiment, the panels are each
numbered and/or otherwise marked and/or labeled to facilitate
assembly. In one embodiment, a crane is used on site to move the
panels from unloading to the assembly location. The crane can lift
each panel, and place it for assembly, for example, by screwing or
welding, as needed.
[0163] Referring to FIG. 9, in one embodiment, a manufacturing
system for manufacturing a steel structure may include any or all
of the following features.
[0164] The system may include a computer-aided design system 910.
The system may be any sort of computer-based software and/or
hardware system that is suitable for the functions described here.
The design system may create a model of the building structure, and
facilitate specification of the panels to be used to construct the
structure. The design system may facilitate generation, or
generate, bills of materials for panels, panel fabrication
drawings, and panel installation drawings in response to panel
selection and panel specifications. In one embodiment, the design
system is a software system that runs on a standard personal
computer configured to have sufficient memory, processing power,
and storage to perform the functions described here. The design
system 910 may interface with databases and/or networked storage,
and other software and hardware systems in the performance of its
functions. In one embodiment, the design system 910 supports
generation of identifiers for each panel in a structure. These
identifiers may be provided on documentation and labels, and may be
associated with manufacturing equipment configuration
parameters.
[0165] The system may include a manufacturing enterprise management
system 920 for managing manufacture of panels. In one embodiment,
the management system 920 facilitates management of manufacture
according to the panel specifications and fabrication drawings
generated by the design system 910. Preferably, the manufacturing
enterprise management system facilitates automated processes, so as
to maintain quality and efficiency. In one embodiment, the
management system tracks each component and subcomponent with a bar
code identifier, such as described with respect to FIG. 19, so that
a worker can determine what needs to be done with the component
simply by scanning the bar code at his or her station. Automated or
computer-based tools at a station will use the bar code to
communicate or interface with the management system 920 to provide
information to the worker to accomplish manufacturing tasks.
[0166] The system may include a material optimizer 930 for
providing metal components for manufacturing panels. In one
embodiment, the optimizer cuts metal material and forms the metal
into a part of a panel according to the specifications for that
panel. As part of the process, each part is assigned an identifier,
and a bar code label. In this way the system can recognize the part
as it appears at each station, and guide the manufacturing process.
In one embodiment, the panel is formed of members, each of which is
cut and formed by the material optimizer 930. In a preferred
embodiment, the optimizer 930 cuts steel from a coil. The panel
components are cut and shaped by the optimizer 930, so as to make
efficient use of the metal material. In one embodiment, the
optimizer 930 may include a de-coiler or straightener, cutter,
overhead gantry system for moving material, and/or a roll
former.
[0167] The system may include a material handling system 940 useful
for moving collections of parts to assembly stations. The parts
then may be assembled as described in the fabrication drawings. In
one embodiment, the material handling system 940 includes a tray
for collecting parts. The parts may include parts made by the
material optimizer and other parts to be used in panel assembly.
The material handling system 940 may include a rails and/or a
conveyor for moving the tray from station to station in a flexible
manner and with relatively minimal effort by workers.
[0168] The system may include a pre-fastener 950 for fastening
parts into a subassembly. The pre-fastener 58 may be any sort of
welder, riveter, screw-gun and/or other fastener that can be used
to assemble metal parts. The pre-fastener 950 may be used to
assemble parts as described in the fabrication drawings. The
pre-fastener 950 may use or include a robotic arm to help
facilitate the efficient manufacture of parts. The pre-fastener 950
may include dynamically-generated aids for manufacture, such as a
laser-guided marking system for indicating where fastening is
needed.
[0169] The system may include a framing table 960 for assembling
parts and/or subassemblies into a panel. In one embodiment, the
framing table 960 includes a screw gun for quickly assembling
pieces into panels. In one embodiment, the panels are assembled as
described in fabrication drawings.
[0170] The system may include a post-fastener (not shown) for
fastening assembled parts. The post-fastener may be, for example,
any sort of welder, riveter, screw-gun and/or other fastener that
can be used to assemble metal parts. The post-fastener may use or
include a robotic arm to help facilitate the efficient manufacture
of parts. The pre-fastener may include dynamically-generated
aids.
[0171] The system may include a sheathing table 970 for applying a
coating or covering to a panel. In one embodiment, the panels are
coated or covered as described in fabrication drawings.
[0172] The system may include an overhead gantry system 980
including a crane and a grabbing device for holding an assembled
panel and collecting panels for delivery.
[0173] Each of these components may have various sub-components
that may be integrated in a manner resulting in efficient panel
production, and building manufacturing process.
[0174] The following is further description of embodiments of these
components. It should be understood that these components have
efficiencies when used together, but it is contemplated that it is
possible for each of the components to be used with none, some, or
all of each of the others, as well as other technology, in a
variety of configurations. It also should be understood that the
embodiments described are exemplary, and variations will be
apparent to those skilled in the art.
Design Application
[0175] Referring to FIG. 10, in one embodiment, a computer aided
design application 1010 enables designers to create a virtual model
1012 of a building structure. The design application 1010 enables a
user, typically a design professional, to create and detail
residential and commercial building structures in light steel. The
design application 1010, may receive as input a collection of
panels that have been previously designed 1014. The design
application 1010, may also take as input structural and/or other
requirements or constraints for the structure to be designed.
[0176] The design application may use previously designed panels
from a panel library 1014, and may also allow for modification
and/or custom design of the panels. The design application 1010 may
include a panel designer 1018, for designing and configuring panels
to be used in the structural model 1012. The design application
also may include a structure designer 1016 for creating and
modifying a model of a structure using the designed panels as
building elements. Structure requirements 1020 may be provided by
building codes, engineers, and so forth. In one embodiment, the
design application facilitates the integration of
engineering/construction knowledge and experience and allows
designers to create complete 3D parametric models based on
specifically defined engineering data. The framing process may run
continuously on creation of any new objects or with any
modifications made to existing objects. Wall, floor and roof panels
may be custom entities and behave as real-life objects. Validation
functionality checks key aspects of the elements drawn in the model
space and generate a report to allow for review and
corrections.
[0177] In some embodiments, the design system contains a parts
database that includes a number (e.g., 10, 14, 25) of base product
profiles and a number (e.g., 4, 8, 12) of joist products. This
database may be architected to allow for future expansion and
configuration. Parts managed in the database are virtual solid
objects with full physical properties including dimensional
measurements in metric and imperial for width, height, gauge
thickness and weight.
[0178] In one embodiment, the design application can run on the
Microsoft Windows operating system and uses an AUTOCAD.TM. design
engine. The AUTOCAD engine provides a platform that is an accepted
standard worldwide for architects and designers alike who are
required to produce working construction drawings. Use of this
standard allows for support and training for users, and allows the
solution to be developed in the Visual C++ and ObjectARX
programming environments.
[0179] The output from the design software 1010 may include
material lists and specifications 130 of individual components used
in the building, fabrication drawings 1032 that describe how a
panel should be manufactured, fabrication data 1034 (e.g., export
data files) such as can be provided to manufacturing management and
manufacturing equipment for manufacture, and panel lists and
installation drawings 1036. Additional output files (e.g., .pnl
files) may be provided to enable integration with standard industry
laser templating technology as well as other types of automated
manufacturing machinery. The drawings and other output data may be
dynamically updated when modifications are made to the building
model.
[0180] Referring briefly to FIG. 11, an exemplary display of a
parametric model shows a portion of a structure that has been
designed using panels according to an embodiment of the invention.
The structure may be assembled from various panels, and manipulated
and modified in the virtual environment. For example, changes can
be made by replacing panels with different panels, or by modifying
the panels themselves.
[0181] Referring to FIG. 12, another view of a parametric model of
a structure is shown, with a display of the physical properties of
a panel. Again, by using panels as a unit of design, it is possible
to efficiently create a structure that can be manufactured.
[0182] Referring to FIG. 13, fabrication drawings, also referred to
as panel drawings, provide information for fabricating panels. An
exemplary material list for a panel as may be included in
fabrication drawings is shown. The material list includes studs,
tracks, and miscellaneous parts. The studs are metal members,
typically vertical, that form the panel. As shown, each stud has a
number as well as a description identifier. The length, quantity,
and locations for knockouts in the stud are provided. Again, the
studs are modular parts that, once designed, can be reused in the
model, and also can be modified for specific or custom use.
[0183] Tracks also are specified in the material list. Tracks are
members, typically horizontal that are used to hold studs in place,
and provide the framing for the panel. Again, each type of track
can be specified in the model, and manufactured to order in the
manufacturing facility. Miscellaneous parts are also specified. In
this example, there are braces, which are cross members used to
help support the structure of the panel. In this example, there are
braces BR and BR-A. Other parts FS22 and UA are also specified.
[0184] The material list may be used to identify the parts that are
needed to assemble a panel. In one embodiment, the material list is
included with a fabrication drawing for a panel, so that the
manufacturing facility personnel can easily determine from the
assembly drawing the parts that are specified and how they should
be put together. Some of the parts themselves may be manufactured,
as described further below, for example by the material optimizer,
and other parts may be purchased externally, and provided for
manufacture.
[0185] Referring to FIG. 14, fabrication drawings may indicate
panels that are assembled in manufacture. An exemplary fabrication
drawing for a wall panel, such as that shown in the figure includes
a materials list as described above.
[0186] For example, the fabrication drawing includes information
listing the metal members, shown as studs S8, S9 and tracks T7, and
other miscellaneous parts (Hole, FS-1, BR, and US-1) that are
included in this exemplary panel. A specification of the type of
sheathing to be attached to the panel is also specified. Panel
statistics such as the size and the weight, in imperial and metric
measures, are listed. Dimensions and size are also summarized
further below.
[0187] In addition to other information, the lot number BLK and the
panel identifier W204X are specified. The panel identifier is
unique for each lot, so that each panel can be specifically
designed and tracked.
[0188] Also included on the drawing is an indication of whether and
how holes should be punched, whether and where batt insulation
should be attached, the location for strap bracing (e.g., front,
back, or both), and an indication of sheathing. Also included is a
diagram that shows how the pieces fit together, and the location(s)
of any brackets, straps, studs, or other parts.
[0189] The panel drawing specifies how the parts should be
assembled, with measurements and connections specified.
[0190] Referring to FIG. 15, an exemplary fabrication drawing for a
panel with a space for a window shows the members that are needed,
as studs and tracks as wells as miscellaneous parts, such as
braces. The size and weight of the panel is specified, as well as
any additional specifications, such as punched holes, batt
insulation, strap bracing, and sheathing. Also, the panel
identifier W203 is shown.
[0191] Referring to FIG. 16, an exemplary fabrication drawing for a
floor panel is shown. Again, studs and tracks are specified, along
with miscellaneous parts. The information in each of these panel
fabrication drawings can be used to select and manufacture the
parts that are needed to manufacture the panel.
[0192] Referring to FIG. 17, a close-up view of a panel drawing
shows the measurements used for fabrication of the panels, as well
as the different parts to be used. Thus, the panel drawing provides
guidance to the manufacturing facility personnel about how the
panel should be assembled from the parts specified.
[0193] Referring to FIG. 18, an exemplary display of data that is
exported from the design software may be imported into a
manufacturing management system. The data includes the types of
parts, and specifications for the parts. The data may also include
other information that may be used to manufacture the various
parts. As shown, the data is in text format, but may be in another
format, such as a self-describing language such as XML, or in a
database or binary format as other examples.
[0194] Referring to FIG. 19, in one embodiment, the design system
supports generation of identifiers for each panel in a structure.
These identifiers may be provided on documentation such as the
fabrication drawings in FIGS. 11, 12, and 13 and labels such as
shown in this figure. A label may include a unique barcode
identifier for the panel (*49334*), as well as an indication of the
project (ARRW-BLK2-11), the Work Order (2226), the Sequence Number
(20), and the panel number (W05X). This identifier may be assigned
to a panel by the CAD system, and used for the assembly of the
panel and for the assembly of the structure. For example,
fabrication drawings may be generated for the panel, and used to
collect the parts for, and assemble the panel. A label with the
identifier may be affixed or kept with the parts for assembly, and
ultimately affixed to the assembled panel, such that the label may
be used to identify the panel in construction, as the structure is
assembled. The label may also include a transceiver, such as an
RFID tag, to allow an identifier to be read wirelessly.
[0195] Installation or construction drawings, for example, may
refer to each of the panels by their identifier. Assigning a unique
identifier to a panel, and using that identifier throughout the
process, provides great efficiency gains in the manufacture and
assembly of structures. These drawings are used by installation
crews on job sites that indicate how each panel needs to come
together on a building site to create a building structure.
Manufacturing Management Application
[0196] Another software application may be integrated with the CAD
application and manages manufacture of the panels. Wireless
technology may be used to track the panel production process. In
one implementation, each panel is bar-coded with labels that may be
tracked throughout the manufacturing process. The application may
identify the materials that are needed and provide an automated
purchasing process. In various implementations, the management
system may provide such enterprise functions such as job costing
(in real time), work order management, inventory management,
receiving, purchasing, shipping and incident tracking, and
production management, all specific to the cold-formed steel
structure industry. The system also facilitates the transfer of
information from the design application to material control systems
so that panels can be fabricated and built.
[0197] In one embodiment, the management software includes a system
administration module, an order management subsystem, a purchasing
subsystem, a production management subsystem, a workforce
management subsystem, a shipping subsystem, and a business
analytics subsystem.
[0198] The system administration module allows for initial system
set-up and configuration. Company and customer/vendor specific
contact information may be defined, as well as interfaces and
connections to other system.
[0199] An order management module may provide a central point of
managing job specific information. This may include project
information and control, and assignment of resources. This also may
include creating work orders for production of panels and trusses.
It allows jobs and work orders to be imported from the design
software, and for the release of work orders for purchasing. It
also may include detailed estimate tracking, milestone dates and
tracking, communications management, incident tracking, and project
change management controls.
[0200] A purchase order subsystem allows creation and management of
detailed purchase orders. For each purchase order, material and
material costs may be allocated to the appropriate account for
reporting and third-party interfaces (e.g., to an accounting
system). Management of purchase orders includes tracking of
purchase order numbers, access and modification of vendor contact
information, access to price lists, and access to a product library
that provides the information needed for appropriate allocation to
account types. For example, the product library may include various
account types (e.g., job, consumables, fixed assets, operating,
non-operating), categories (e.g., building, structural cold-formed
steel, communication, computer, consumables, structural hot-formed
steel, insulation, non-structural cold-formed steel, etc.),
sub-categories (e.g., breakshape, light gauge steel, clip angles,
etc.), product codes, product descriptions, and units of
measure.
[0201] The purchase order subsystem also allows for material
ordering (e.g., per project or per panel), adding an order to a
batch, viewing standard material for a panel, exporting of data to
a vendor file format, and updating job management information based
on order status.
[0202] A production management subsystem allows plant managers to
allocate and redirect orders to production according to customer
timelines and the availability of labor and materials. The
production management system receives purchase orders that are
created, and allows for creation, editing, and managing of work
orders. It also enables the generation of bar code data for use in
production. The production management system also allows users with
appropriate permissions to view the queue of jobs, and to manage
and release jobs to production. The production management system
facilitates the sequencing of jobs, work orders, and panels, such
that the panels can be piled as desirable for efficient use upon
installation.
[0203] The production management subsystem also allows for accurate
tracking of all materials and panels in production by status type,
for example: picking, pre-welding, GFT, post-welding, sheathing,
staging, loading, or post production (e.g., rework, meeting,
material handler/truss, or maintenance).
[0204] The production management subsystem also allows for
integration with panel identification (e.g. bar coding) technology,
and allows wireless scanners to integrate and provide job-specific
status for all products in production. Specific labels may be
printed from laser printers on the shop floor allowing for shipping
and receiving to clearly track materials. The production management
system allows for scanning of identification cards, as well as for
selection and tracking of production tasks. The production
management system also enables loose material tracking, and panel
exception management.
[0205] A workforce management subsystem provides detailed project
and task time tracking to manage labor requirements. For example,
badge swiping cards provide accurate clock-in and clock-out times.
The workforce management subsystem allows for creation and
modification of employee information, such as job type (e.g.,
picker, assembler, welder, sheather, material handler, maintenance,
stager, shipper, or other), employee type (e.g., plant employee,
plant supervisor, office staff), and other employee information.
The workforce management subsystem may track employee's time, and
calculate information for payroll, based on the time records. The
workforce management subsystem may provides an interface to an
employee time manager kiosk that allows employees to check in
before and out after each shift. The workforce management subsystem
also can be used to track productivity, by comparing the work
completed by an employee in the time that he or she is at work in
the plant.
[0206] A shipping subsystem controls movement of panels through the
loading and shipping process. A loading module may provide
real-time information about the projects that are loaded. A display
of each trailer may show the locations of the panels. A shipping
module may display all unique loads shipped with date, time, and
trailer number. It also may display panel count for the
trailer.
[0207] An invoicing subsystem manages and controls invoices on a
contract-by-contract basis. Invoices related to construction
projects may be billed on a percentage of completion basis, and may
be managed such that the design, supply, and installation are
billed as separate milestones. In one embodiment, the invoicing
subsystem can break out the separate aspects of the design portion
(e.g., signing of a proposal, submission of permit drawings, and
submission of shop drawings), the supply portion (e.g., blocks,
levels, walls, floors, and roof), and the install portion (e.g.,
blocks, levels, walls, floors, and roof installation, and in some
cases a breakdown between stick framing and interior). On a regular
interval, the invoicing subsystem can provide an accounting for a
project and issue appropriate invoices.
[0208] A business analytics subsystem may provide information for a
status report regarding the operation of the manufacturing
facility. An exemplary production report is as shown in TABLE 1
below. As can be seen from the exemplary report, it may include the
number of employees that are working, and where those resources are
deployed. In can provide statistics on the status of the work
performed, and the panels that have been picked, pre-welded,
assembled at GFT, post-welded, sheathed, staged, and loaded.
TABLE-US-00001 TABLE 1 This Report was Generated and E-mailed by
GEM Nov. 20, 2006 2:58:08 PM Morning Shift Stats Employees Signed
In: 29 Panels ***Manufacturing Index: 980*** Panel Employees: 18
Picked: 86|2.6 men Pre-Welding: 68|2.44 men GFT: 99|7.53 men
Post-Welding: 85|3.57 men Sheathing: 9|1 men Staged: 101|1748
pcs|1.41 men Loaded: 156|3011 pcs|0.47 men Current HPU: 1.56
Current MPP: 5.4 Area Produced: 541 sq. M (5823.28 sq. ft.) Weight
Produced: 4329 Kg (9543.81 lbs.) GFT: Table 1: 19|389 pcs|934.52
sq. ft.|1793.13 lbs. Table 2: 26|491 pcs|1111.48 sq. ft.|2919.23
lbs. Table 3: 19|279 pcs|954.01 sq. ft.|1621.41 lbs. Table 4:
35|599 pcs|1358.73 sq. ft.|3114.43 lbs. Staged: Brentcliff Stacked
Towns 101 (Hyde Park Phase 4 and 5): Loaded: Aspen Heights Building
B: 1 on #52186 Aspen Heights Building B: 1 on #573028 Brentcliff
Stacked Towns 25 on #488821 (Hyde Park Phase 4 and 5): Brentcliff
Stacked Towns 49 on #488822 (Hyde Park Phase 4 and 5): Brentcliff
Stacked Towns 78 on #573022 (Hyde Park Phase 4 and 5): Quality
Control Panels Checked: 0 Pass: 0 Fail\Rework: 0 Trusses Truss
Employees: 4 Cutting: 8 h 55 m GTT: 77 Staged: 79 Loaded: 0 Current
HPU: 0.79 GTT: Table 1: 48 Table 2: 29 Staged: Brentcliff Stacked
Towns 79 (Hyde Park Phase 4 and 5): Loaded: Other Other Employees:
3 Hours: 28 h 14 m Employees Not Scanned Into C4, T1, or Other:
Employee Name Signed In Signed Out A 05:32 AM 12:30 PM B 05:32 AM C
05:37 AM D 05:52 AM E 05:52 AM
[0209] Other exemplary reports that may be provided by the business
analytics subsystem include workforce management (e.g., employees
per day, total labor hours, hourly labor per project, employee time
daily report, and project list), manufacturing analytics (e.g.,
amounts that have been: picked, pre-welded, GFT, post-welded,
sheathed, staged, loaded; statistics such as HPU and MPP/Day;
allocations of workers by job type; and pieces staged), process
analytics (e.g., employee production, build production, employee
productivity, project report, product process, drawings issued,
panels process report, and panels loaded/shipped), management
controls (e.g., orders not received, received not picked, staged
not loaded, and incomplete panels), and job costing (e.g., cost per
panel, project cost, and category cost). Real-time notifications
also may be provided, for example by email to designated
distribution lists.
[0210] Referring to FIG. 20, a process for the operation of a
manufacturing facility using a management system as just described
begins with the configuration of a new project (STEP 2010). This
may be accomplished, for example, using the system administration
subsystem. This may be accomplished, for example, by a project
manager. The project manager can create the new project, and
provide all contact information and other details.
[0211] When the project has been created, the project manager may
then create work orders (STEP 2040). This may be accomplished, for
example, by a project manager. This may be accomplished, for
example, using the order management subsystem. The order management
system may be used to create work orders, and specify lots of
panels, levels, and phases for the project. The project manager may
make use of information provided by a design system. For example,
the project manager may create the work orders and then import
material lists (STEP 2030) for the work orders, based on the
information from the design system. In this way, the project
manager can quickly specify accurately the materials that are
needed to fill the work order.
[0212] Once the work orders have been created, then the material
for the jobs can be ordered (STEP 2040). This may be accomplished,
for example, by purchasing or accounting personnel. This may be
accomplished, for example, by using the purchase order subsystem
described above. An export file may be created in a vendor-specific
format.
[0213] Work orders and/or panels may be released to the ordering
process, and when the materials arrive, they may be received into
the production management system. For example, receiving department
personnel may indicate that the material is now available for
production.
[0214] When the material is available, and the timing is
appropriate, the jobs, work orders, and panels may be sequenced and
scheduled (STEP 2050). This may be accomplished, for example, by a
production or project manager. This may be accomplished, for
example, using a production management subsystem as described
above. As the jobs come up for manufacture, they will be provided
to the manufacturing personnel.
[0215] When the parts needed for the assembly, including parts that
are manufactured by machines and parts that were purchased from
outside vendors, and it is the panel's turn in the sequence, it is
ready for assembly. Labels will be printed for that panel (STEP
2060), and kept with, or affixed to, the collection of parts. This
may be accomplished, for example, by a picker, or other line
worker. This may be accomplished, for example, using the production
management subsystem as described. By generating the labels
dynamically with the picking of the components, it is possible to
change the sequence in which future panels will be manufactured at
any time.
[0216] Throughout the production process, the manufacture of the
panels may be monitored and information provided to plant
management (STEP 2070). This may be accomplished, for example, by
plant management, such as a production or project manager. This may
be accomplished, for example, using a business analytics subsystem
as described above.
[0217] Following production, the staged panels may be loaded to
trailers, as well as any additional loose materials (STEP 2080).
Bills of lading and shipping lists may be created. This may be
accomplished, for example, by shipping personnel. This may be
accomplished, for example, using the shipping subsystem described
above.
[0218] Additional tasks that may be performed are job costing (at
the front end) and accounting and invoicing as the project
proceeds.
[0219] It should be understood that alternative embodiments, and/or
materials used in the construction of embodiments, or alternative
embodiments, are applicable to all other embodiments described
herein.
[0220] The invention may be embodied in other specific forms
without departing from the spirit or essential characteristics
thereof. The foregoing embodiments, therefore, are to be considered
in all respects illustrative rather than limiting the invention
described herein. Scope of the invention is thus indicated by the
appended claims, rather than by the foregoing description, and all
changes that come within the meaning and range of equivalency of
the claims are intended to be embraced therein.
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