Truss manufacturing method and system

Abstract

Methods and systems are provided for making one or more structural stud trusses without the need for using a jig when the truss is assembled. In one embodiment, data identifying a plurality of structural stud members for making the truss is generated. The data includes data for each stud including physical stud parameters and one or more locations for an alignment guide where another member is to connect with it. A roll forming machine is controlled with the generated data to produce the plurality of stud members whereby the roll forming machine applies one or more alignment guides onto each member based on locations identified in the generated data. Finally, after all or some of the stud members are formed, the members are assembled to form the truss using the alignment guides to align connecting members with each other in order to fasten them together.

1 . A method of making a truss, comprising: 
 generating data identifying a plurality of structural stud members for a truss, the structural stud members to be formed from a roll forming machine, the data for each stud including physical stud parameters and one or more locations for an alignment guide;    controlling the roll forming machine with the generated data to produce the plurality of metal stud members, the roll forming machine applying one or more alignment guides based on the locations in the data; and    assembling the studs to form the truss, the act of assembling including using the alignment guides to align connecting members to each other in order to fasten them together.    
   
   
       2 . The method of  claim 1 , wherein the one or more studs are “C” channel metal studs.  
   
   
       3 . The method of  claim 1 , wherein the act of applying the one or more alignment guides includes punching a hole in a stud at each alignment guide location.  
   
   
       4 . The method of  claim 3 , wherein the act of securing connecting stud members includes inserting a peg into one or more sets of associated alignment holes as they are fastened together with one or more screws.  
   
   
       5 . The method of  claim 1 , further including controlling the roll forming machine to apply an identifier proximal to each alignment guide indicating how many fasteners are to be used at the connection corresponding to the alignment guide.  
   
   
       6 . The method of  claim 1 , wherein the truss is a back-to-back truss comprising “C” channel structural steel studs.  
   
   
       7 . The method of  claim 1 , wherein the data is generated by an executing software module that receives as input information generated by a design program that at least partially designs the truss.  
   
   
       8 . A truss made in accordance with the method of  claim 1 .  
   
   
       9 . In a roll-forming system that includes a roll forming machine and a processor for generating data to control the roll-forming machine to create a plurality of metal stud members for making a truss, a memory media having instructions that when executed by the processor cause it to perform a method comprising: 
 receiving data that identifies the plurality of stud members and where they are connected to one another to form the truss; and    generating data for controlling the roll-forming machine to create the studs, the generated data causing the roll-forming machine to apply an alignment guide on each stud at a location where it is to be connected to another stud.    
   
   
       10 . The memory media of  claim 9 , wherein the roll-forming machine is controlled to punch a hole for each alignment guide.  
   
   
       11 . The memory media of  claim 9 , wherein the roll-forming machine is controlled to apply an assembly tag onto each member proximal to an alignment guide.  
   
   
       12 . The memory media of  claim 9 , wherein an alignment guide is placed on a member's centerline where it intersects with a centerline from a connecting member.  
   
   
       13 . A kit for making a truss, comprising: 
 one or more chord members formed using structural studs each having a web portion; and    one or more web members formed using structural studs each having a web portion, the chord and web members each having an alignment guide located on its web portion where it is to connect with another chord or web member thereby enabling the truss to be assembled without the need for a jig.    
   
   
       14 . The kit of  claim 13 , wherein the chord members have flange portions that oppositely face flange portions on the web members when the chord and web members are connected together to form a truss.  
   
   
       15 . The kit of  claim 13 , wherein the chord and web member structural studs are formed from “C” channel studs.  
   
   
       16 . The kit of  claim 13 , wherein the web and chord members have assembly tags next to the alignment guides.  
   
   
       17 . The kit of  claim 13 , wherein the alignment guides are formed from holes punched out of the web portions.  
   
   
       18 . The kit of  claim 17 , wherein the holes are non-rotatable holes.  
   
   
       19 . The kit of  claim 13 , wherein the structural stud members are formed out of light gauge steel roll using a roll form machine.  
   
   
       20 . A truss formed from the kit of n  claim 13.