Modular housing system

Abstract

A modular production system and method for producing wall panels of a modular building. The system includes a worktable, a plurality of telescoping tools mounted over the worktable, an overhead tram disposed adjacent the worktable, and a plurality of material supply bridges movably supported on the overhead tram so as to be movable over the worktable. The method of manufacturing a panel of a modular structure includes moving the first material supply bridge over a worktable to place panels of sheeting on the worktable, and then moving a second material supply bridge over the worktable to place steel members for the construction of a steel frame. A third material supply bridge is then moved over the worktable to apply adhesive on the sheeting in a pattern mirroring the steel frame.

1 . A modular production system for producing wall panels of a modular building, the system comprising: 
 a worktable;    a plurality of telescoping tools mounted over the worktable;    an overhead tram disposed adjacent the worktable; and    a plurality of material supply bridges movably supported on the overhead tram so as to be movable over the worktable in a longitudinal direction thereof.    
   
   
       2 . The modular production system as claimed in  claim 1 , further comprising a controller for controlling operation of the worktable and the material supply bridges.  
   
   
       3 . The modular production system as claimed in  claim 2 , wherein the controller comprises a computer.  
   
   
       4 . The modular production system as claimed in  claim 1 , further comprising a module assembly table for receiving, storing and assembling wall panels produced at the worktable.  
   
   
       5 . The modular production system as claimed in  claim 1 , wherein the worktable includes longitudinal encoder tracks supported on a plurality of telescoping pylon tubes for setting the vertical position of the longitudinal encoder tracks.  
   
   
       6 . The modular production system as claimed in  claim 5 , wherein the pylon tubes are movable horizontally toward and away from a central axis of the worktable.  
   
   
       7 . The modular production system as claimed in  claim 5 , wherein each of the longitudinal encoder tracks includes at one encoder actuator head.  
   
   
       8 . The modular production system as claimed in  claim 1 , wherein each of the plurality of material supply bridges is independently movable in the longitudinal direction of the worktable, and the material supply bridges are arranged so that they can cross over or under each other while performing independent production procedures.  
   
   
       9 . The modular production system as claimed in  claim 1 , wherein the plurality of material supply bridges comprises a first supply bridge for supplying sheeting material to the worktable, a second supply bridge for supplying steel members to the worktable, and a third supply bridge for supplying adhesive and insulation to the worktable.  
   
   
       10 . The modular production system as claimed in  claim 9 , wherein the first material supply bridge includes opposing sloping pallets for supporting panel sheets, and a sheet placement device for moving the sheets from the first material supply bridge to the worktable.  
   
   
       11 . The modular production system as claimed in  claim 9 , wherein the second material supply bridge includes welders, metal press joining equipment, and screw driving devices.  
   
   
       12 . The modular production system as claimed in  claim 1 , wherein the third material supply bridge includes an adhesive dispensing device and an insulation spray device.  
   
   
       13 . The modular production system as claimed in  claim 1 , wherein each of the plurality of telescoping tools comprises two structural members having interlocked bearing surfaces to permit the tool to contract and expand in length to accommodate different panel widths.  
   
   
       14 . The modular production system as claimed in  claim 1 , wherein the plurality of telescoping tools comprises a transverse telescoping linear encoded router, a transverse telescoping encoded material locator, a telescoping linear encoded diamond saw, and a transverse telescoping linear encoded nailer.  
   
   
       15 . The modular production system as claimed in  claim 14 , wherein the ends of the telescoping linear encoded diamond saw can be skewed to enable the saw to make cuts at an angle to the longitudinal axis of the worktable.  
   
   
       16 . The modular production system as claimed in  claim 5 , wherein each of the plurality of telescoping tools comprises encoder actuator heads supported on the longitudinal encoder tracks.  
   
   
       17 . A method of manufacturing a panel of a modular structure, the method comprising: 
 moving a first material supply bridge over a worktable in a longitudinal direction of the worktable to place panels of sheeting on the worktable, wherein the first material supply bridge is supported on an overhead power tram; and    moving a second material supply bridge over the worktable in the longitudinal direction of the worktable to place steel members for the construction of a steel frame, wherein the second material bridge is supported on the overhead power tram.    
   
   
       18 . The method of manufacturing a panel of a modular structure as claimed in  claim 17 , further comprising connecting the steel members to form edge beams and intermediate beams of the steel frame.  
   
   
       19 . The method of manufacturing a panel of a modular structure as claimed in  claim 18 , further comprising moving a third material supply bridge over the worktable in a longitudinal direction of the worktable to apply adhesive on the sheeting in a pattern mirroring the steel frame, wherein the third material bridge is supported on the overhead power tram.  
   
   
       20 . The method of manufacturing a panel of a modular structure as claimed in  claim 19 , further comprising lowering the steel frame so as to embed the steel frame in the adhesive on the surface of the sheeting.