Methods for automated assembly of roof panel structures

Abstract

A portable roof panel structure assembly mechanism that may be transported to a construction site and that is used to automatically assemble roof panel structures at the site. The assembly mechanism includes a purlin feeder, subpurlin clamping mechanisms and feeders, and a diaphragm feeder. The purlin feeder lifts a purlin into position, and advances the purlin into an assembly station. The subpurlin feeders insert a subpurlin into each of a plurality of subpurlin clamping mechanisms, and the clamping mechanisms advance into the assembly station and hold the subpurlins against the section of the purlin that has been advanced. The diaphragm feeder places a diaphragm onto the subpurlins and the purlin at the assembly station. The components are attached by automatic nailers.

What is claimed is:  
     
         1 . A method of assembling a roof panel structure, comprising: 
 using a first automated system, advancing at least one subpurlin into an assembly station and against at least one purlin; and    attaching the at least one subpurlin to the at least one purlin.    
     
     
         2 . The method of  claim 1 , wherein the purlin is advanced into the assembly station by a second automated system.  
     
     
         3 . The method of  claim 2 , further comprising: 
 advancing at least one diaphragm into the assembly station and against the at least one subpurlin and the at least one purlin; and    attaching the at least one diaphragm to the at least one subpurlin and the at least one purlin.    
     
     
         4 . The method of  claim 3 , wherein the diaphragm is advanced into the assembly station by a third automated system.  
     
     
         5 . The method of  claim 1 , further comprising: 
 advancing at least one diaphragm into the assembly station and against the at least one subpurlin and the at least one purlin; and    attaching the at least one diaphragm to the at least one subpurlin and the at least one purlin.    
     
     
         6 . The method of  claim 5 , wherein the diaphragm is advanced into the assembly station by a second automated system.  
     
     
         7 . The method of  claim 5 , further comprising, after attaching the at least one subpurlin to the at least one purlin: 
 indexing the at least one purlin through the assembly station;    advancing an additional at least one subpurlin against the advanced at least one purlin; and    attaching the additional at least one subpurlin to the advanced at least one purlin.    
     
     
         8 . The method of  claim 7 , further comprising: 
 advancing an additional at least one diaphragm against the additional at least one subpurlin; and    attaching the additional at least one diaphragm to the additional at least one subpurlin.    
     
     
         9 . The method of  claim 1 , wherein the first automated system comprises a carriage for advancing the at least one subpurlin into the assembly station.  
     
     
         10 . The method of  claim 9 , wherein the at least one subpurlin comprises a bracket for attaching to the purlin, and further comprising lifting at least a bracket end of the subpurlin prior to advancing the at least one subpurlin against the at least one purlin.  
     
     
         11 . The method of  claim 10 , further comprising lowering the bracket end as the subpurlin is advanced against the purlin.  
     
     
         12 . The method of  claim 9 , further comprising, prior to advancing the at least one subpurlin into the assembly station, automatically feeding the at least one subpurlin onto the carriage.  
     
     
         13 . The method of  claim 1 , wherein the at least one subpurlin comprises a bracket for attaching to the purlin, and further comprising lifting at least a bracket end of the subpurlin prior to advancing the at least one subpurlin against the at least one purlin.  
     
     
         14 . The method of  claim 1 , further comprising lowering the bracket end as the subpurlin is advanced against the purlin.  
     
     
         15 . The method of  claim 1 , further comprising sensing the width of the at least one subpurlin.  
     
     
         16 . The method of  claim 1 , further comprising sensing the length of the at least one subpurlin.  
     
     
         17 . The method of  claim 1 , further comprising adjusting the height of the at least one purlin prior to advancing the at least one subpurlin into the assembly station.  
     
     
         18 . The method of  claim 1 , further comprising, after attaching the at least one subpurlin to the at least one purlin: 
 indexing the at least one purlin through the assembly station;    advancing an additional at least one subpurlin against the advanced at least one purlin; and    attaching the additional at least one subpurlin to the advanced at least one purlin.    
     
     
         19 . A method of assembling a roof panel structure, comprising: 
 using a first automated system, advancing at least one purlin into an assembly station;    advancing at least one subpurlin against the at least one purlin in the assembly station; and    attaching the at least one subpurlin to the at least one purlin.    
     
     
         20 . The method of  claim 19 , further comprising: 
 advancing at least one diaphragm into the assembly station and against the at least one subpurlin and the at least one purlin; and    attaching the at least one diaphragm to the at least one subpurlin and the at least one purlin.    
     
     
         21 . The method of  claim 20 , wherein the diaphragm is advanced into the assembly station by a second automated system.  
     
     
         22 . The method of  claim 19 , further comprising, after attaching the at least one subpurlin to the at least one purlin: 
 using the first automated system, indexing the at least one purlin through the assembly station;    advancing an additional at least one subpurlin against the advanced at least one purlin; and    attaching the additional at least one subpurlin to the advanced at least one purlin.    
     
     
         23 . The method of  claim 22 , further comprising: 
 advancing an additional at least one diaphragm against the additional at least one subpurlin; and    attaching the additional at least one diaphragm to the additional at least one subpurlin.    
     
     
         24 . The method of  claim 19 , further comprising adjusting the height of the at least one purlin prior to advancing the at least one subpurlin into the assembly station.  
     
     
         25 . A method of assembling a roof panel structure, comprising: 
 using a first automated system, advancing at least one subpurlin into an assembly station;    uniting the at least one subpurlin and at least one diaphragm in the assembly station; and    attaching the at least one subpurlin to the at least one diaphragm.    
     
     
         26 . The method of  claim 25 , wherein the diaphragm is advanced into the assembly station by a second automated system.  
     
     
         27 . The method of  claim 25 , wherein the first automated system comprises a carriage for advancing the at least one subpurlin into the assembly station.  
     
     
         28 . The method of  claim 27 , further comprising, prior to advancing the at least one subpurlin into the assembly station, automatically feeding the at least one subpurlin onto the carriage.  
     
     
         29 . The method of  claim 25 , further comprising sensing the width of the at least one subpurlin.  
     
     
         30 . The method of  claim 25 , further comprising sensing the length of the at least one subpurlin.  
     
     
         31 . A method of assembling a roof panel structure, comprising: 
 using a first automated system, advancing at least one diaphragm into an assembly station and against at least one subpurlin; and    attaching the at least one diaphragm to the at least one subpurlin.    
     
     
         32 . The method of  claim 31 , wherein the subpurlin is advanced into the assembly station by a second automated system.  
     
     
         33 . The method of  claim 31 , further comprising sensing the alignment of the at least one diaphragm prior to advancing at least one diaphragm into an assembly station.  
     
     
         34 . The method of  claim 33 , further comprising altering the alignment of the at least one diaphragm responsive to the sensing.  
     
     
         35 . The method of  claim 34 , further comprising using a second automated system, automatically attaching the at least one diaphragm to the at least one subpurlin.  
     
     
         36 . A method of assembling a roof panel structure, comprising: 
 using a first automated system, advancing a purlin into an assembly station;    using a second automated system, advancing at least one subpurlin into the assembly station and against the purlin;    using a third automated system, advancing at least one diaphragm into the assembly station and against the at least one subpurlin and the at least one purlin; and    attaching the at least one diaphragm to the at least one subpurlin and the purlin.    
     
     
         37 . The method of  claim 36 , further comprising a fourth automated system for automatically attaching the diaphragm to the at least one subpurlin and the purlin.  
     
     
         38 . The method of  claim 36 , further comprising, after attaching the at least one diaphragm to the at least one subpurlin and the purlin: 
 using the first automated system, indexing the purlin through the assembly station;    using the second automated system, advancing an additional at least one subpurlin against the advanced purlin;    using the third automated system, advancing an additional at least one diaphragm into the assembly station and against the at least one subpurlin and the advanced purlin; and    attaching the additional at least one subpurlin and the additional at least one diaphragm to the advanced purlin.