System and method for the automated assembly of trusses

Abstract

The present invention relates to systems and methods used to assemble trusses composed of wooden components. The system comprises at least one station for cutting lumber into truss components (i.e., cords and web members), a station for position the cord members relative to one another, a station for positioning the web member relative to the cord members for attachment, and a station for securing the web members to the cord members and/or other web members in a predetermined sequence.

1 . A system for the automated assembly of a truss, comprising:
 a first station having one or more automated saw systems for cutting lumber into truss components, including a plurality cord members and web members, wherein the automated saw systems comprise a controller programmed with a specification to cut the cord members and web members in a predetermined order representative of an order in which the components are assemble relative to one another;   a second station, in conveyor communication with the first station, wherein the cord members are supported and positioned relative to one another form a perimeter of the truss, and wherein the second station comprises a controller that is programmed to position the cord members relative to one another in accordance with the specification;   a third station, in conveyor communication with the first station, that supports the cut web members which are positioned relative to one another in a predetermined order of attachment to the cord members and in accordance with the specification;   means, at the second station or third station and responsive to a controller, for engaging a web member at the third station and transferring the web member to the second station and positioning the web member relative to the cord members for attachment; and,   means, at the second station and responsive to a controller, for securing two or more truss components in accordance with the specification.   
   
   
       2 . The system of  claim 1 , wherein the second station further comprises an assembly table and a plurality of grasping members for grasping cord members and for orienting the cord members relative to one another on the assembly table, and wherein the grasping members are laterally movable on the assembly table for orienting a cord member at an angle relative to an adjacent cord member. 
   
   
       3 . The system of  claim 2 , wherein the grasping members comprise a register for engaging an inner portion of the cord member and a plurality of rollers for engaging an outer portion of a cord member. 
   
   
       4 . The system of  claim 2 , wherein the second station further comprises a plurality of passive rollers for conveying cord members in a downstream direction along the assembly table. 
   
   
       5 . The system of  claim 2 , wherein the grasping members further comprise a pivot arm, wherein the pivot arm is movable from a first position where the register and plurality of rollers engage a cord member to a second position where the register and plurality of rollers do not engage the cord member. 
   
   
       6 . The system of  claim 1 , wherein the third station comprises:
 a robotic arm for grasping a cut web member conveyed to the third station; and   means for verifying the dimensions of the cut web member; and   a controller for comparing first stored values for the dimensions of the cut web member with second values obtained from the means for verifying.   
   
   
       7 . The system of  claim 1 , wherein the means for securing comprises a robotic arm mounted for lateral movement over a portion of an assembly table of the second station or third station, wherein the robotic arm comprises one or more staple guns and one or more clamping members for orienting and securing two or more truss components. 
   
   
       8 . The system of  claim 1 , wherein the means for securing comprises means for applying adhesive to a junction of two or more truss components. 
   
   
       9 . The system of  claim 1 , further comprising means for affixing a connector plate to the two or more truss components, wherein the means for affixing a connector plate comprises:
 a plurality of bins for storing a plurality of connector plates;   a robotic arm for grasping two or more connector plates from one of the plurality of bins;   a press for affixing the two or more connector plates comprising upper and lower magnetized platens mounted for up and down movement relative to one another, wherein the press is mounted for lateral movement over an assembly table of the second or third station for affixing the two or more connector plates at a junction of the two or more truss components.   
   
   
       10 . The system of  claim 1 , wherein the bin assembly comprises:
 a base;   a plurality of bins mounted on the base, wherein the plurality of bins comprise a tray and a connector plate storage compartment for storing a plurality of connector plates; and   means, within a bin, for dispensing two or more connector plates from the connector plate storage compartment to a front portion of the tray.   
   
   
       11 . The system of  claim 10 , wherein the means for dispensing two or more connector plates comprises:
 an engagement member mounted for lateral movement on the tray; and   an actuating mechanism for causing movement of the engagement member toward the connector plate storage compartment when activated.