AU2018203187A1 - Interfacing mesh and bridge delivery - Google Patents

Abstract

A production line includes a multitude of different work 5 stations for manufacturing a reinforced autoclaved aerated concrete product in which at one work station a mesh reinforcement is matched with a carrier for the mesh so that the correct carrier is used to transport the mesh to the moulding station for use when moulding the reinforced 10 product using a computer controlled interface. The carrier is a frame having a bridge assembly with a plurality of rods, the number and type of which are dedicated exclusively to engaging with one type of mesh only. Matching of the carrier and mesh using the computer 15 interface allows carriers with the correct number of rods to be matched with the correct mesh so that the mesh is secured to the correct carrier for transportation along the production line to the moulding station for moulding the required product. The advance of using a computer 20 interface to match the mesh and carrier increases the efficiency of the manufacturing process by reducing mismatching of the mesh and product. 10238722_1 (GHMatters) P104796.AU.1 8/05/18 46 - 47 -o 50 -> 52

Description

BACKGROUND

Many manufacturing processes require one or other component of a finished product to be transported through 25 various steps of a complex manufacturing process taking place in a manufacturing facility, such as a factory, to enable components of the finished product to be correctly located in sequence at the required places and at the required times for incorporation into the finished 30 product. Often a conveyor is used to transfer the components from one location to a required location or locations. In a simple manufacturing process in which the component is a substantially uniform and constant component, the delivery of the substantially identical 35 components in sequence is relatively straightforward.

However, in more complex manufacturing processes in which the one component can have a variety of different forms or

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2018203187 08 May 2018 configurations but which are critical to the characteristics or properties of the finished product, it is a requirement that the correct form of the component be delivered in the correct sequence by carriers or conveyors 5 adapted to the specific form of the component for incorporation into the correct finished product. The selection of the correct form from the range of different forms of the component requires flexibility in the manufacturing process so that the correct carrier can be 10 selected to match the correct form of the component to transfer that component as required in the manufacturing process. One example of a manufacturing process in which a range of different components must be conveyed by a range of dedicated conveyors exclusive to one form of the 15 component is the manufacture of reinforced lightweight building products, such as reinforced cementitious building products of different dimensions and end uses which require reinforcements of different sizes, styles, configurations or the like, each of which must be conveyed 20 by different dedicated conveyor or carrier to transport the one form of the different reinforcements exclusively.

One issue of existing production lines is their limited flexibility which requires operators to manually relocate 25 carriers and parts of the carriers to accommodate changes in the finished product. Manually relocating carriers and their attendant parts increases the time required to change the carrier from one configuration to another configuration to accommodate the new different reinforcement which decreases the efficiency of the production line, and hence add to the cost of production so that the price of the final product is less competitive in the market place.

Each different product width and reinforcement type made in the manufacturing process requires a different carrier setup so that, in the past, it was necessary to select the

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2018203187 08 May 2018 correct carrier to match the different product. In a complex production line, the changeover from one type of carrier to another type of carrier would be frequent, further reducing the efficiency of the production line and 5 increasing the chance of errors occurring due to mismatching of the exact form of the reinforcement with the incorrect type of carrier.

Mismatching of the reinforcement with the incorrect carrier resulted in disruptions to the production line for manufacturing the reinforced lightweight building products which disruptions interrupt production of the finished product and/or produces an off-specification final product that is unusable necessitating discarding of the off15 specification product because the individual product is not suitable for its intended purpose.

Accordingly, there is a need for a device and method used in manufacturing processes for producing reinforced lightweight concrete products that substantially accurately and consistently matches the exact form of the reinforcement component used in the manufacturing process with dedicated conveyors or carriers for transferring the component exclusively by reducing the incidence of errors or inaccuracies occurring leading to a reduction in the number and extent of disruptions and interruptions to the manufacturing processes and/or reducing the amount of offspecification products produced in the manufacturing process. The devices and methods described herein seek to address the shortcomings of existing devices and methods resulting from inaccurately and erroneously mismatching reinforcements with carriers .

SUMMARY

According to one form of the present invention there is provided a method of transferring a reinforcement,

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2018203187 08 May 2018 comprising the steps of selecting the reinforcement conveying the reinforcement to a work station providing a frame arrangement having a multitude of bridge assemblies the bridge assemblies having a multitude of engaging elements matching the reinforcement with the frame arrangement using an interface controller to form a matched frame arrangement conveying the matched frame arrangement to the workstation moving the frame arrangement or the reinforcement or both relative to one another to facilitate cooperative engagement of at least some of the multitude of engaging elements of the frame arrangement with the reinforcement to secure the reinforcement to the frame arrangement for facilitating transportation of the reinforcement, wherein the number, position and/or orientation of the engaging elements of the matched frame arrangement corresponds to the size, shape and/or configuration of the reinforcement to be secured to the bridge assembly so that 30 the reinforcement moves from the work station in accordance with corresponding movement of the frame arrangement from the workstation to convey the reinforcement.

According to one form of the present invention there is provided a method of transferring a reinforcement during a manufacturing operation

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2018203187 08 May 2018 the method comprising the steps of providing the reinforcement, conveying the reinforcement to a work station in a first direction, providing a frame arrangement having a multitude of bridge 10 assemblies, the bridge assemblies having a multitude of engaging elements, matching the reinforcement with the frame arrangement using an interface controller to form a matched frame arrangement, conveying the matched frame arrangement to the workstation 20 in a second direction, securing the reinforcement to the bridge assembly by moving the frame arrangement and/or the reinforcement relative to one another to facilitate engagement of at 25 least some of the engaging elements with the reinforcement to secure the reinforcement to the frame arrangement, and moving the frame arrangement in a third direction from the workstation to transfer the reinforcement from the workstation in the third direction for subsequent transportation as part of the manufacturing operation.

According to one form of the present invention there is provided a transfer line within a manufacturing facility for transferring a reinforcement from a work station during a

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2018203187 08 May 2018 manufacturing operation the transfer line comprising at least one work station the work station for receiving and retaining a reinforcement received from a first direction the workstation for receiving a frame arrangement from a second direction, the frame arrangement having a multitude of bridge assemblies provided with a multitude of engaging elements 15 extending from the bridge assemblies, the multitude of engaging elements of the frame arrangements being matched to the reinforcement for conveying the reinforcement using an interface controller 20 intermediate the frame arrangement and the reinforcement, wherein when the frame arrangement or the reinforcement or both move relative to one another, at least some of the multitude of engaging elements cooperatively engage with 25 the reinforcement to secure the reinforcement enabling movement of the reinforcement from the workstation in accordance with corresponding movement of the frame arrangement from the workstation to transfer the reinforcement as part of the manufacturing operation.

According to one form of the present invention there is provided a workstation for securing a reinforcement and a frame arrangement to one another for enabling transfer of the reinforcement from the workstation during a manufacturing process, the workstation having a base portion for receiving and

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2018203187 08 May 2018 retaining the reinforcement in a first configuration, the reinforcement being received by the workstation in a first direction, the base portion being movable between a transfer position for introducing the reinforcement to the workstation in the first direction and an engaged position for enabling cooperative engagement of the reinforcement and the frame 10 arrangement for transfer from the workstation, the frame arrangement having a multitude of bridge assemblies, the bridge assemblies having a multitude of engaging elements extending outwardly therefrom, the engaging elements being adapted to cooperatively engage with the reinforcement, the frame arrangement and the reinforcement being associated with one another using an interface controller, the workstation for receiving the frame arrangement in a 25 second direction, the frame arrangement being matched to the reinforcement, wherein the engaging elements cooperatively engage with the reinforcement in response to relative movement of the frame arrangement and/or reinforcement to one another to secure the reinforcement to the engaging elements so that 35 movement of the frame arrangement in a third direction moves the reinforcement from the work station in the third direction to transfer the reinforcement.

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EMBODIMENTS

In one form the manufacturing process or manufacturing operation is for producing lightweight building products, typically cementitious lightweight building products, more typically reinforced lightweight concrete building products, such as for example, reinforced autoclaved aerated concrete products (AAC), preferably in the form of 10 reinforced blocks, reinforced slabs, reinforced panels, reinforced bricks, reinforced sheets or other similar products. Preferably, the manufacturing process is for making HEBEL® reinforced lightweight concrete products by CSR Building Products Ltd.

In one form, the frame arrangement is a movable frame arrangement, typically movable along a designated track or pathway within a manufacturing facility, more typically in sequence between different spaced apart locations within 20 the manufacturing facility. Forms of the frame arrangement include a carriage or trolley or similar for conveying the frame arrangement. In one form the carriage or trolley includes an overhead lifting device or similar, such as for example a crane, a hoist, an overhead gantry, 25 or the like. However, it is to be noted that movement of the frame arrangement can be by any suitable or convenient means and in any suitable or convenient manner.

The frame arrangement also includes a frame or framework, ³⁰ typically a generally rectilinear framework module. In one form the framework module includes two longitudinally extending spaced apart framework members, one located at or towards either long side of the bridge assembly so as to form two long framework members. The framework module also includes transversely extending cross bars or cross framework members. In one form, there are 3 transversely extending cross framework members. However, it is to be

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2018203187 08 May 2018 noted that the framework module can have any suitable or convenient shape, form, size, configuration, style or the like .

Forms of the frame optionally include locking fittings or fixtures for allowing the bridge assemblies to be positively engaged, fixed or locked into position to secure the bridge assemblies to the frame thereby preventing unwanted movement of the bridge assemblies or inadvertent disengagement of the bridge assemblies from the frames .

Forms of the frame arrangement include a transversely extending bridge bar or cross bar, typically a plurality of individual bridge bars, each of which extends transversely between the two spaced apart longitudinally extending framework members of the framework module. Forms of the bridge bar have end fittings located at either end of each individual bridge bar for allowing coupling of both ends of individual bridge bars to the framework members to locate the bridge bars with respect to the framework module. Preferably, the bridge bars are movable in the lengthwise extending direction of the framework module and are removable from the framework as required. It is to be noted that the bridge bars should be positively engaged to the framework so that the bridge bars are securely held in place while being used but can then be released so that the bridge bars can be relocated or replaced with different bridge bars.

Forms of the bridge bar are provided with a multitude of spaced apart apertures for receiving the engaging elements which together form a bridge assembly. The apertures are at predetermined spaced apart locations along the length of the bridge bar to span between the sides of the framework module. In forms of the bridge assembly the apertures receive respective engaging elements. In one

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2018203187 08 May 2018 configuration all of the apertures receive an engaging element whereas in other configurations not all apertures receive and engage engaging element therein so that some apertures are free or empty of an engaging element.

Further, it is to be noted that the number and position of the engaging elements or rods is determined by the thickness of the panel that is being manufactured. Accordingly, if the reinforcement is in the form of a cage, then having too many rods will not allow the reinforcement to be attached.

Different bridge assemblies are stored in a magazine. Frames or frameworks are always in circulation and different bridge assemblies are added to the frames to create the different frame arrangements required, which is determined by the type of panel being produce and hence the frame arrangement which needs to be matched to the reinforcement being made by relocating or substituting the bridge assemblies on the frame arrangement to ensure that the correct bridge assemblies are on the frame arrangement as required.

The bridge assembly includes a multitude of engaging elements in the form of elongate bars, rods, shafts, needles, spikes, or similar acicular elongate metal sections, strips or lengths. Although the rods can have any suitable or convenient shape, configuration, or size or be of any type, preferred forms are substantially cylindrical and provided with tapering ends or reducing diameter distal sections for allowing easy insertion of the rods into and through the reinforcement, particularly the spaces in the mesh forming the reinforcement and/or aerating mixture from which the AAC product is manufactured.

As forms of the rod need to be able to hold or attach to

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2018203187 08 May 2018 the reinforcement in some way, any suitable or convenient form of engagement arrangement can be employed. This can be in the form of clips or, more usually, the tips of the rods are provided with a notch to hold the wire of the 5 reinforcement mesh.

The reinforcement can be of any suitable or convenient form. In one form the reinforcement is in the form of a mesh, sieve, screen, perforated sheet or other plate 10 having apertures or openings.

In reinforced products having a double mesh/cage reinforcement, the spacers of the mesh are formed in such a way as to facilitate the attachment of the rod to the 15 reinforcement.

The perforations of the mesh may be in any suitable or convenient pattern or grouping or spacing or arrangement or similar.

Preferably, the mesh comprises an interconnected network of longitudinally extending rods or wires and transversely extending rods or wires defining openings, apertures, spaces, gaps or similar intermediate the interconnecting 25 rods or wires, typically of a square or rectangular shape in the form of an open grid or similar. A particularly preferred form of mesh is a mesh made from Rebar or similar.

The reinforcement can be a single sheet, a double sheet, or two or more interconnected sheets in which each sheet is substantially planar. Forms of the reinforcement also include spacers for interconnecting the two or more spaced apart planar sheets of mesh. Forms of the mesh include a three-dimensional cage or similar.

Forms of the work station receive the reinforcement in a

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2018203187 08 May 2018 first direction which in one form is from a section of the manufacturing process for making the mesh, such as for example, the mesh producing section or machine where the mesh is formed by welding individual rods or wires to each 5 other to form the interconnected array of longitudinal and transverse rods which manufacture occurs in a reinforcement manufacturing area or section. Typically, the first direction is in a direction from the mesh manufacturing area or section where the welding machine is 10 located to the work station. However, it is to be noted that the overall layout of the device within the manufacturing facility can be any convenient or suitable arrangement.

Forms of the work station receive the frame assembly in a second direction, which is a direction from the bridge assembly storage area or section of the layout of the manufacturing process. Preferably, the first direction and the second direction are collinear but opposite directions to one another so that the workstation receives the reinforcement from the directly opposite side, to the side corresponding to the direction from where the frame assembly is received. However, the second direction can be any suitable or convenient direction or combination of directions.

Forms of the work station move the frame arrangement, together with attached reinforcement, in a third direction to exit the workstation. Typically, the third direction is perpendicular to the first and second collinear directions, more typically in a perpendicular direction which is in the direction towards the centre or internally within the manufacturing facility. However, the third direction can be a combination of two or more directions such as a combination of horizontal and vertical directions. Furthermore, the third direction is any suitable or convenient direction or combination of

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2018203187 08 May 2018 directions .

In one form each framework module comprises a multitude of individual bridge bars, with each bridge bar having multiple engaging elements. Each framework module can have from about 2 to about 10 individual bridge bars, typically from about 3 to about 8 individual bridge bars.

In some forms of the bridge assembly the individual bridge 10 bars are releasably locked into position within the framework module. Forms of the lock include a clamp, clip, restraint, clasp, retainer or similar.

Forms of the lock or locking arrangement can have any 15 suitable or convenient form or arrangement such as for example the lock could be a screw style clamp, pin in hole arrangement, spring clip or spring clamp arrangement. The lock can be released by screwing, pinching, clamping, pushing, pulling or other suitable movement or combination 20 of movements. In fact, different forms of lock could be created for any type of releasing mechanism.

During production of the reinforced AAC panel, frame arrangements and bridge assemblies having cleaned and 25 waxed rods locked into place on the respective bridge bars, move into a location from where the frame arrangement with attached bridge assemblies can be transferred to a bridge assembly storage area. In one form the frame arrangement indexes from the location in 30 preparation for the bridge assemblies to be lifted or hoisted by a suitable lifting device, such as for example, a gantry robot or similar.

In one form the gantry robot manipulates the bridge 35 assemblies in the following manner. If the frame arrangement is correctly set up, the gantry will not do anything and allow the frame arrangement to continue in

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2018203187 08 May 2018 the direction of the workstation for engaging with the reinforcement mesh. However, if the bridge assemblies in the frame arrangement are the correct type but located in incorrect positions, the gantry will relocate the bridge 5 assemblies to the correct positions along the framework.

The framework will then continue along the production line in the direction towards the workstation for engaging with the mesh. On the other hand, if the bridge assemblies are of an incorrect type, the bridge assemblies are relocated 10 to the bridge assembly storage area or similar, such as for example, to a storage magazine in which rows of substantially identical bridge assemblies are stored in blocks or groups in preparation for subsequent selection and positioning in a future frame arrangement setup.

Correct bridges assemblies stored in the bridge assembly storage area are selected and moved from the magazine and are placed in the correct position on the frame module by the gantry robot.

In forms of the layout within the manufacturing facility, typically in the form of a factory, the interface between the mesh manufacturing area and the bridge assembly storage area or storage magazine is controlled so as to match selected bridge assemblies with the selected mesh 25 reinforcement so that the particular arrangement of the engaging elements of the bridge assembly are compatible with the particular mesh. Typically, the matching and/or selection of an individual bridge assembly with an individual mesh is computer controlled, typically an interface computer controller associated with both the manufacture and selection of the mesh and the selection of the bridge assembly, such that characteristics of the mesh to be manufactured are identified by the computer to enable a bridge assembly to be selected from the store of 35 waiting bridge assemblies in the bridge assembly storage area, which selected bridge assembly has the correct characteristics, configuration, size, and the like to be

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2018203187 08 May 2018 compatible with the mesh selected from the mesh manufacturing area or mesh set up area prior to actual manufacture. After selection from the bridge assembly storage area, the selected bridge assembly is positioned by the gantry robot into a framework in the correct position along the framework, so to create a frame arrangement that is matched to the mesh being manufactured. The frame arrangement once assembled is conveyed to the workstation to arrive almost simultaneously with or shortly after or shortly before the arrival of the corresponding mesh reinforcement to enable the mesh to be secured to the frame arrangement for transfer to other areas or sections of the manufacturing process .

It is to be noted that the timing sequence of respective movement of the mesh and frame arrangement is timed for optimal efficiency of production of the finished products.

In one form the reinforcement is made in a reinforcement manufacturing station, area or section, typically when the reinforcement is in the form of a mesh or similar, a mesh manufacturing station, area or section. In one form the individual components of the mesh are welded together by a suitable welding machine system. In one form the welding machine system controls movement of empty frame arrangements at a suitable location within the overall production line, such as for example at, near or close to the bridge assembly storage area so that the particular bridge assemblies are matched to the particular mesh being produced by the welding machine system. Owing to the welding machine system taking control of the selection and movement of the required bridge assemblies, the correct mesh and correct frame arrangement with correct bridge assemblies arrive simultaneously at the work station for engagement to secure the mesh to the frame arrangement for further transport along or around the production line.

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In forms, the number, position and/or orientation of the engaging elements attached to the bridge bar corresponds to the size, shape and/or configuration of the reinforcement, particularly corresponding to the size and location of the openings or spaces within the mesh of the reinforcement so that the rods can be received through the spaces within the mesh to enable the rods to cooperatively engage with the mesh to secure the mesh to the rods, and 10 hence to the bridge bar, and to the frame arrangement so that movement of the frame arrangement also moves the reinforcement in unison with the frame arrangement to transfer the reinforcement from the work station as part of the overall manufacturing process for forming the product.

In forms of the bridge assembly, the rods are pivotally mounted to the bridge bar allowing movement of the rods, typically rotational movement about the central axis of 20 each individual rod to rotate that rod from an engaged position in which the rod is in contact with the mesh, and a release position enabling the rod to be removed from contact with the mesh, such as for example, to disengage from individual rods in the mesh, and hence from the product during the manufacturing process. Forms of the rod are provided with an engager for engaging the mesh. Typical examples of the engager include a barb, arrow head or similar having a tapering or sloping surface for facilitating engagement and disengagement of the rod with 30 the mesh. Forms of the engager are fixed whereas other forms are movable, such as for example, being retractably movable.

The selection of the correct bridge assembly, of the correct position of the bridge assemblies in a frame arrangement, and the selection of the correct reinforcement are controlled by a suitable controller. In

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2018203187 08 May 2018 one form, a suitable controller is an interface controller, typically a computer-controlled interface controller which is connected intermediate the mesh set up station or mesh manufacturing station and the bridge assembly storage area containing the various different forms of bridge assemblies having different configurations of groups of engaging elements.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of devices and methods used in the manufacturing processes for the manufacture of reinforced AAC building products will now be described by way of example to illustrate aspects of the scope of protection with reference to the accompanying drawing in which:

Figure 1 is a schematic flow chart of one form of a layout suitable for use in matching one form of reinforcement with a dedicated carrier in the manufacturing process of reinforced AAC building products.

Figure 2 includes a series of schematic perspective views of one form of the framework arrangement including the various components of the framework arrangement and bridge 25 assembly.

Figure 3 is a schematic top plan view of one part of an overall layout showing selection of the framework module having the correct bridge assembly.

Figures 4-1 to 4-5 are a series of schematic side elevation views of the method of attaching the reinforcements to the bridge assembly by engagement of the reinforcement with the engaging rods of the bridge assembly.

Figure 5 is a schematic top plan view of one form of the

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2018203187 08 May 2018 bridge assembly storage area showing one form of a device for selecting and transferring individual bridge assemblies .

Figure 6 is a schematic side elevation view of the bridge assembly storage area of figure 5.

Figure 7 is a schematic end elevation view of the bridge assembly storage area of figure 5.

Figure 8 is a schematic side elevation view of one form of the locking arrangement for locking one form of bridge bar to the bridge assembly/framework module.

Figure 9 is a schematic side elevation view of one method of attaching a bridge bar to a frame.

SPECIFIC DESCRIPTION

One form of a layout within a manufacturing facility, such as for example, a factory for making lightweight reinforced autoclaved aerated concrete products, will now be described.

The layout, generally denoted as 10, includes a number of separately identifiable areas or sections in which individual steps in the overall manufacturing process occur, or individual steps or stages occurring in the overall manufacturing process are to be described, as are the results obtained by using one or more of the individual devices and/or steps in the overall process are being described.

One form of the process is the manufacture of reinforced

AAC panels using a moulding process allowing the expansion of a suitable aerating mixture introduced into individual moulds to form the aerated product in which the

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2018203187 08 May 2018 reinforcement is totally embedded within the product.

One section of layout 10 is a reinforcement raw material storage area 12 for storing suitable raw material such as steel rods, wire or similar, typically in the form of rolls, for use in manufacturing suitable reinforcements, typically in the form of a mesh of interconnected longitudinal and transverse rods or wires. The individual rods or pieces of wire are assembled together in an assembly or set up area 14, where the individual rods and wire are loaded into a jig or similar of a mesh welding machine or similar for welding to form the mesh. It is to be noted that the set up area 14 is linked to a central interface controller 16 for determining the exact configuration of the mesh being set up in the set up area 14. In one form the various parts of the jigs of the set up area are interchangeable to accommodate changes in accordance with the specific requirements of the actual mesh being formed at the time. The central interface controller 16 is required in order to identify the correct configuration of the mesh being manufactured in accordance with the dedicated carrier required for transferring the particular assembled mesh through the manufacturing process (to be described in more detail later).

The individual mesh having the required configuration is manufactured in mesh manufacturing area 18 where the assembly of interconnected bars is welded together to produce the mesh for transportation to another location 30 within the factory and for subsequent embedding within the block formed in the moulding operation. In one form, set up area 14 and mesh manufacturing area 18 are or may be the same area or section.

The size, style, configuration and form of the mesh being produced in mesh manufacturing area 18 is determined by and in accordance with the requirements of the AAC panel

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2018203187 08 May 2018 within which it is to be embedded in the moulding stage of the manufacturing process. Usually, the mesh has a single sheet or a double sheet in which each individual sheet is interconnected by a multitude of spacers to form a cage.

The characteristics of the mesh are inputted into a suitable computer controlled interface control system at location 16 and the particular mesh is manufactured using welding or similar techniques to join the individual rods of the mesh together. After manufacture of the particular 10 mesh in mesh manufacturing area 18, the mesh is conveyed by a suitable conveyor, typically in the form of a trolley or other wheeled carriage or similar, more typically an overhead conveyor or similar, even more typically also including a framework module, to a work station 20 where 15 the mesh reinforcement is placed on a movable base 22 of workstation 20 in a suitable configuration and position, such as for example, extending upwardly from base 22, such as is shown in figures 4. The movable base with attached reinforcement moves from one side of the workstation to adopt a position at or towards the other side of the work station.

Base 22 of work station 20 is provided with a platform which is capable of movement in use in a substantially 25 vertical direction from a lower transport position or configuration or condition as shown in figures 4-1, 4-2 and 4-5 to an upper engaged position, configuration or condition as shown in figures 4-3 and 4-4, to attach the reinforcement to bridge assembly 24 having bridge bar 26 30 and a plurality of downwardly depending engaging members or elements extending from bridge bar 26. Typically, the downwardly depending engaging members or elements are in the form of spaced apart substantially parallel elongate rods 28. It is to be noted that a multitude of individual 35 reinforcement mesh 30 are loaded onto the trolley or carriage and/or the base portion of the workstation so that many individual meshes 30 are treated simultaneously.

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Simultaneously with individual meshes 30 being manufactured and transported to workstation 20, bridge assemblies are prepared and stored in a storage area or region of the general layout of the factory in close proximity to the position of the workstation 20 having the reinforcements loaded onto the base portion. In one form the storage area, region or section is a storage magazine 32. Each base assembly 24 comprises a generally transversely extending bridge bar 26 with a plurality of spaced apart receiving apertures located there along and a plurality of elongate bars 28 depending downwardly from the transverse bridge bar. It is to be noted that the number of downwardly depending elongate bars 28 matches the configuration of the reinforcement mesh 30 to be attached to the bridge assembly so that in some embodiments, there is a lesser number of downwardly depending bars than the number of available receiving apertures, and in other embodiments each receiving aperture is provided with a downwardly depending bar. Further, it is to be noted that the selection of the relevant bridge assembly from the store of bridge assemblies in magazine 32 is in accordance with the sequenced arrival of the particular mesh reinforcement for being embedded in the particular AAC block being manufactured containing the mesh reinforcement. In one form the production of the particular mesh reinforcement and matching to the particular bridge assembly is computer controlled at the central control interface 16 so that the correct bridge assembly arrives at the correct time for engagement with the correct mesh reinforcement.

After the correct bridge assembly has been selected and attached to a waiting framework module or similar, ³⁵ typically in the form of framework 40, it is transferred via a suitable trolley or carriage and framework arrangement, to the workstation where it is positioned

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2018203187 08 May 2018 substantially vertically above the loaded base portion 22 and reinforcement 30. It is to be noted that any suitable carriage or trolley or other wheeled vehicle can be used to transport a multitude of similar bridge assemblies simultaneously. One form of the framework arrangement is illustrated in figure 2. Figure 2 illustrates one form of the engaging element 28, one form of the bridge/bridge bar/crossbar 26, one form of the bridge assembly 24 comprising bridge bar 26 and engaging elements 28, one form of frame 40 and one form of the framework arrangement comprising all of the components referred to immediately above.

In one form the bridge assembly includes a substantially rectilinear framework arrangement having two longitudinally extending outer frame members and three or four transversely extending frame members forming an interconnected array. Each bridge bar 26 is provided with a suitable fitting in the form of a coupling at either end for fitting over the longitudinally extending framework members and either side of the frame arrangement. Thus, the carriage containing the multiplicity of correct bridge assemblies is transported to the workstation where it is positioned so that the downwardly depending rods are located substantially vertically above the multitude of vertically oriented reinforcements .

When the bridge assemblies are located in alignment above the respective reinforcements, the base of the work station is raised in sequence or in steps while reciprocating from side to side in controlled sequenced steps to move reinforcement 30 first one way and then the other in steps to facilitate insertion of the tapered end of the downwardly depending rods into and through the gaps or spaces of the mesh so that the rods cooperatively engage with the mesh to secure the mesh to the rods and hence to the bridge bar and to the respective bridge

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2018203187 08 May 2018 assembly, as shown more particularly in the sequence of figures 4-1 to 4-5. When mesh 30 is securely connected to the bridge assembly, base 22 of workstation 20 is lowered and returned to the original position at the first side of 5 the work station in preparation for receiving a further group of mesh reinforcements for attaching to a further group of bridge assemblies using the process as just described, such as shown more particularly in figure 4-5.

Simultaneously with lowering of the base of the work station, the bridge assembly suspended from above, exits the work station in a direction substantially perpendicular to the direction of movement of the base of the work station and of the carriage, bringing the bridge assemblies into alignment with the workstation for transfer to subsequent treatment stations, including stations for treating the reinforcement.

One form of a subsequent treatment station is a coating station for coating mesh 30, such as for example, at a coating station 44 for dipping or immersing the reinforcement 30 and intermeshed rods 28 in a suitable vessel, such as for example, a protective coating or similar anti-corrosion coating for the reinforcement to preserve the reinforcement against corrosion or deterioration when embedded in the AAC block or panel.

Another form of subsequent treatment station is a heating station 46, area or section, such as for example an oven, ³⁰ typically a tunnel oven, particularly an oven located sequentially after the coating bath used for coating the reinforcement with a protective coating in order to cure the protective coating under the effects of heat. In one form the heating occurs in a linear tunnel oven through which a suitable carrier travels. In one form the suitable carrier engages with the framework arrangement for conveying the multitude of bridge assemblies and

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2018203187 08 May 2018 attached reinforcements .

After exiting the oven, the framework containing the bridge assemblies is conveyed to a storage area or section

47 for storing the frameworks containing the bridge assemblies and attached reinforcements for use in subsequent steps in the overall manufacturing process. In one form there are different lines of frameworks containing different bridge assemblies arranged so that similar bridge assemblies are all located in the one line but other lines contain different bridge assemblies, but of the same type as each other. The storage area or section 47 acts as a buffer or reservoir or storage magazine for storing reinforcements to be selected as required for conveying to moulding station 50 or area or section, particularly the exact mould in moulding station 50 for forming the panels having the embedded reinforcement. An overhead crane or gantry is moved to above the selected framework of bridge assemblies for transporting the framework to the relevant mould and lowering the reinforcement and rods into the cavity of the mould subsequent to introduction of the moulding mixture. However, in some embodiments the reinforcement is lowered simultaneously with the moulding mixture rising to fill the mould cavity so that the rods holding the reinforcement are located within the moulding mixture.

The moulding station 50 contains a multitude of open topped moulds in which the AAC panels are formed after the 30 introduction of a suitable aerating mixture through the open top or other entry port located in the base or sides of the mould.

On arriving at a location immediately above and in alignment with the selected mould, the framework arrangement is disengaged from the carrier and the framework arrangement containing the bridge assemblies and

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2018203187 08 May 2018 secured reinforcement is lowered into the mould whereupon the aerating mixture is introduced into the mould. The aerating mixture is added to the lower portion of the mould and expands upwardly to cover the reinforcement so 5 as to embed the reinforcement totally within the finished block or panel. As the aerating mixture rises, engaging rods 28 are rotated, typically through about 90° to release the end of the rods from mesh 30 so that the rods can be withdrawn from the mesh and from the mould by 10 raising the bridge assembly vertically upwards to an extent so that the lower distal ends of the rods are collectively above the upper level of the aerating mixture in the mould at the fullest expansion of the mixture. It is to be noted that the upper edge of the reinforcement is 15 below the upper level of the aerated mixture when fully expanded so that the reinforcement is totally embedded within the mixture so that when secured, the reinforcement is not exposed at any surface of the AAC block or panel, even when the block is divided into individual reinforced 20 panels.

With the rods free of the mould, the framework containing the bridge assemblies but now not the reinforcement which by now is covered by the aerating mixture and remains in 25 the mould, is returned in the direction towards the storage magazine by the carrier to a line with a further treatment area for treating the bridge assemblies, particularly the rods, typically in individual steps or operations .

At the commencement of the further treatment area, the engaging rods are rotated to reach their original position in which the rods are locked in the receiving apertures of the bridge bar of the bridge assembly for secure retention 35 in place in preparing the bridge bar and/or bridge assembly for a further cycle of the steps of attaching to new reinforcements .

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In one form the first step in the further treatment is an engagement rod brushing area 52 where residual aerated mixture and other unwanted debris or contaminants are removed from the rods in a suitable manner, such as for example, by mechanical abrasion of the rods. In one form the mechanical abrasion is brushing of the rods to form a surface substantially free of contamination.

An optional further cleaning station 53 is provided in some forms of the layout to assist in further cleaning of the rods .

The framework arrangement of bridge assemblies with now cleaned rods is conveyed to a further treatment vessel, in the form of a bath, typically containing a suitable material for coating the rods, such as for example wax contained in a wax bath 54, for applying a coating of wax to the rods by immersing or dipping the rods into the wax 20 bath.

The framework arrangement having the bridge assemblies with waxed rods is conveyed to a suitable waiting location 56 sited within the factory where the framework arrangement is collected by an overhead gantry or similar for transporting the framework arrangement and bridge assemblies to the bridge assembly storage area or region 32 where the individual frame arrangements are reconfigured, if required, for subsequent types reinforcements being produced. The bridge assemblies being removed, if required, are deposited at one of the selected bridge assembly storage stacks for containing more or less substantially identical bridge assemblies and rods .

In one form, the layout includes multiple storage lines or multiple blocks of storage or groups in which the bridge

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2018203187 08 May 2018 assemblies in each line, block or group are substantially the same as all of the others in that one line, block or group but different to the bridge assemblies in any one of the other lines, blocks or groups. The storage of the bridge assemblies acts as a buffer or reservoir of suitable bridge assemblies to supply the assemblies as required, by an individual bridge assembly being able to be selected at will for location on a suitable framework arrangement in accordance with the particular reinforcement being selected for manufacture so that the framework arrangement with the correct bridge assemblies can be transferred to the work station for attachment to the correct reinforcement as occurs in the work station as previously described.

In one form, the layout or production line has two levels of bridge assemblies in the magazine to increase the storage capacity of the bridge assemblies. Ideally, eight or more different bridge assembly types could be stored in 20 different sections or areas within the magazine. In forms, the numbers of different bridge assemblies can be different depending upon the numbers of different blocks/panels being produced so that a greater number of bridge assemblies relating to the most commonly produced 25 types of product would be stored in the respective magazine and a lesser number of bridge assemblies would be stored in the respective magazines for the less commonly produced blocks/panels.

In operation of this part of the manufacturing facility, a signal is sent to coordinate manufacture of a suitable mesh reinforcement and the assembling of a framework of suitable bridge assemblies so that the selected framework arrangement can be transported to the workstation simultaneously with the manufacture and transportation of the multitude of reinforcements so that the reinforcements match the bridge assemblies and frame arrangement allowing

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2018203187 08 May 2018 attachment of the reinforcement to individual frame arrangements at the workstation.

ADVANTAGES

The devices and methods described as the layout or part of the layout within the manufacturing facility have one or more of the following advantages.

The layout and the movement of framework modules and bridge assemblies throughout the layout, particularly along the manufacturing production line provides enhanced flexibility of the production plan for the finished product. Provided the required numbers of suitable bridge assemblies are available in the bridge assembly storage magazine, production can continue to produce finished product to the required specification.

The production line/layout of the factory requires no manual set up apart from initially making up bridge assemblies by inserting rods into the respective apertures of the bridge bars. Once a bridge assembly has been prepared, no further manual intervention is required usually.

In one form the mesh welding machine is associated with two work stations to enhance flexibility and throughput of production by allowing the mesh welding machine to proceed through its cycle without having to pause.

In forms of the system/layout the complexity of the rules dictating movement of the framework module, particularly the insertion and removal lifting devices, such as the cranes, gantries or hoists is reduced considerably.

There are clearly defined lines of interfacing between individual factory systems, including both mechanical

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2018203187 08 May 2018 systems and electrical systems. The information required to define the position of the bridge arms on the framework modules is only required by the welding machine and the point at which the bridge bars are positioned. The computer controlled interface controller only needs to know that the framework module coming into consideration for matching with the corresponding mesh is complete and ready to go and to leave framework modules at a particular point within the layout or production line.

The use of the framework buffer is a lot less complex allowing more effective process flow through the production line to improve throughput of finished products .

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any 20 other country.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary 25 implication, the word comprise or variations such as comprises or comprising is used in an inclusive sense,

i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

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Claims (70)

1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

   1. A method of transferring a reinforcement,

   5 comprising the steps of selecting the reinforcement conveying the reinforcement to a work station providing a frame arrangement having a multitude of bridge assemblies the bridge assemblies having a multitude of engaging 15 elements matching the reinforcement with the frame arrangement using an interface controller to form a matched frame arrangement conveying the matched frame arrangement to the workstation moving the frame arrangement or the reinforcement or 25 both relative to one another to facilitate cooperative engagement of at least some of the multitude of engaging elements of the frame arrangement with the reinforcement to secure the reinforcement to the frame arrangement for

   30 facilitating transportation of the reinforcement, wherein the number, position and/or orientation of the engaging elements of the matched frame arrangement corresponds to the size, shape and/or 35 configuration of the reinforcement to be secured to the bridge assembly so that the reinforcement moves from the work station in accordance with

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   2018203187 08 May 2018 corresponding movement of the frame arrangement from the workstation to convey the reinforcement.
2. 2. A method of transferring a reinforcement during a

   5 manufacturing operation the method comprising the steps of providing the reinforcement, conveying the reinforcement to a work station in a first direction, providing a frame arrangement having a multitude of

   15 bridge assemblies, the bridge assemblies having a multitude of engaging elements ,

   20 matching the reinforcement with the frame arrangement using an interface controller to form a matched frame arrangement, conveying the matched frame arrangement to the

   25 workstation in a second direction, securing the reinforcement to the bridge assembly by moving the frame arrangement and/or the reinforcement relative to one another to facilitate engagement of

   30 at least some of the engaging elements with the reinforcement to secure the reinforcement to the frame arrangement, and moving the frame arrangement in a third direction

   35 from the workstation to transfer the reinforcement from the workstation in the third direction for subsequent transportation as part of the

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   2018203187 08 May 2018 manufacturing operation .
3. 3. A transfer line within a manufacturing facility for transferring a reinforcement from a work station

   5 during a manufacturing operation the transfer line comprising at least one work station the work station for receiving and retaining a reinforcement received from a first direction the workstation for receiving a frame arrangement

   15 from a second direction, the frame arrangement having a multitude of bridge assemblies provided with a multitude of engaging elements extending from the bridge assemblies, the multitude of engaging elements of the frame arrangements being matched to the reinforcement for conveying the reinforcement using an interface controller intermediate the frame arrangement and the 25 reinforcement, wherein when the frame arrangement or the reinforcement or both move relative to one another, at least some of the multitude of engaging elements

   30 cooperatively engage with the reinforcement to secure the reinforcement enabling movement of the reinforcement from the workstation in accordance with corresponding movement of the frame arrangement from the workstation to transfer the reinforcement as part 35 of the manufacturing operation.
4. 4. A workstation for securing a reinforcement and a

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   2018203187 08 May 2018 frame arrangement to one another for enabling transfer of the reinforcement from the workstation during a manufacturing process,
5. 5 the workstation having a base portion for receiving and retaining the reinforcement in a first configuration, the reinforcement being received by the workstation

   10 in a first direction, the base portion being movable between a transfer position for introducing the reinforcement to the workstation in the first direction and an engaged

   15 position for enabling cooperative engagement of the reinforcement and the frame arrangement for transfer from the workstation, the frame arrangement having a multitude of bridge

   20 assemblies, the bridge assemblies having a multitude of engaging elements extending outwardly therefrom,

   25 the engaging elements being adapted to cooperatively engage with the reinforcement, the frame arrangement and the reinforcement being associated with one another using an interface

   30 controller, the workstation for receiving the frame arrangement in a second direction,

   35 the frame arrangement being matched to the reinforcement,

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   2018203187 08 May 2018 wherein the engaging elements cooperatively engage with the reinforcement in response to relative movement of the

   5 frame arrangement and/or reinforcement to one another to secure the reinforcement to the engaging elements so that movement of the frame arrangement in a third direction moves the reinforcement from the work station in the third direction to transfer the

   10 reinforcement.

   5 . A workstation or method according to any preceding claim in which the manufacturing process or manufacturing operation is for producing reinforced

   15 autoclaved aerated concrete products (AAC)in the form of reinforced blocks, reinforced slabs, reinforced panels, reinforced bricks, reinforced sheets or other similar reinforced products .

   20
6. 6. A workstation or method according to any preceding claim in which the frame arrangement is a movable frame arrangement, movable along a designated track or pathway within a manufacturing facility in sequence between different spaced apart locations

   25 within the manufacturing facility.
7. 7. A workstation or method according to any preceding claim in which the frame arrangement includes a carriage or trolley or similar for conveying the

   30 frame arrangement.
8. 8 . A workstation or method according to any preceding claim in which the carriage or trolley includes an overhead lifting device or similar including a crane, 35 a hoist, an overhead gantry, or the like.
9. 9. A workstation or method according to any preceding

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   2018203187 08 May 2018 claim in which the frame arrangement comprises a frame or framework of a generally rectilinear framework module having two longitudinally extending spaced apart framework members, one located at or

   5 towards either long side of the bridge assembly so as to form two long framework members, and at least one transversely extending cross bar or cross framework members spanning between the longitudinally extending framework members .
10. 10. A workstation or method according to any preceding claim in which the framework or frame arrangement comprises three transversely extending cross framework members .
11. 11. A workstation or method according to any preceding claim in which the framework or framing arrangement further comprises one or more locking fittings or fixtures for allowing the bridge assemblies to be

    20 positively engaged, fixed or locked into position to secure the bridge assemblies to the frame thereby preventing unwanted movement of the bridge assemblies or inadvertent disengagement of the bridge assemblies from the frames .
12. 12. A workstation or method according to any preceding claim in which the framework or frame arrangement includes at least one transversely extending bridge bar or cross bar.
13. 13. A workstation or method according to any preceding claim in which the framework or frame arrangement comprises a plurality of individual bridge bars, each of which extends transversely between the two spaced

    35 apart longitudinally extending framework members of the framework module .

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    2018203187 08 May 2018
14. 14. A workstation or method according to any preceding claim in which the bridge bar has end fittings located at either end of each individual bridge bar for allowing coupling of both ends of individual

    5 bridge bars to the framework members of the framework or framing arrangement to locate the bridge bars with respect to the framework module.
15. 15. A workstation or method according to any preceding

    10 claim in which the bridge bars are movable in the lengthwise extending direction of the framework module and/or are removable from the framework as required.

    15
16. 16. A workstation or method according to any preceding claim in which the bridge bars are releasably securable to the frame or framework arrangement to be positively engaged to the framework so that the bridge bars are securely held in place while being

    20 used but are released for relocation or replacement with different bridge bars.
17. 17. A workstation or method according to any preceding claim in which the bridge bar is provided with a

    25 multitude of spaced apart apertures for receiving the engaging elements wherein the apertures and engaging elements form a bridge assembly.
18. 18. A workstation or method according to any preceding

    30 claim in which the apertures are at predetermined spaced apart locations along the length of the bridge bar to span between the sides of the framework module .

    35
19. 19. A workstation or method according to any preceding claim in which the apertures receive respective engaging elements .

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    2018203187 08 May 2018
20. 20. A workstation or method according to any preceding claim in which each of the apertures receives a respective engaging element or not all of the

    5 apertures receive and engage with an engaging element therein so that some apertures are free or empty of an engaging element.
21. 21. A workstation or method according to any preceding

    10 claim in which the number and position of the engaging elements or rods is determined by the thickness of the panel which is being manufactured.
22. 22. A workstation or method according to any preceding

    15 claim in which the reinforcement is in the form of a cage. This
23. 23. A workstation or method according to any preceding claim in which the workstation further comprises a

    20 magazine for storing different bridge assemblies.
24. 24. A workstation or method according to any preceding claim in which the frames or frameworks circulate around the manufacturing facility and different
25. 25 bridge assemblies are added to the frames at selected work stations to create the different frame arrangements required for manufacturing the building product wherein the selection of the bridge assembly is in accordance with the type of panel being

    30 produced.

    25. A workstation or method according to any preceding claim in which the frame or frame arrangement is matched to the reinforcement being made by relocating

    35 or substituting the bridge assemblies on the frame arrangement to ensure that the correct bridge assembly is located upon the correct frame or frame

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    2018203187 08 May 2018 arrangement as required.
26. 26. A workstation or method according to any preceding claim in which the bridge assembly includes a

    5 multitude of engaging elements in the form of elongate bars, rods, shafts, needles , spikes, or similar acicular elongate metal sections, strips or lengths .

    10
27. 27. A workstation or method according to any preceding claim in which the rods are substantially cylindrical and provided with tapering ends or reducing diameter distal sections for allowing easy insertion of the rods into and through the spaces of the mesh

    15 reinforcement and/or aerating mixture from which the

    AAC product is manufactured.
28. 28. A workstation or method according to any preceding claim in which the rod is securely attached to the

    20 mesh reinforcement using clips or notches provided at the tips of the rods to hold the wire of the reinforcement mesh.
29. 29. A workstation or method according to any preceding

    25 claim in which the reinforcement is in the form of a mesh, sieve, screen, perforated sheet or other plate having apertures or openings.
30. 30. A workstation or method according to any preceding

    30 claim in which the reinforcement is a double sheet or layer mesh or a cage reinforcement having spaces wherein the spacers of the mesh are formed to facilitate attachment of the rod to the reinforcement.
31. 31. A workstation or method according to any preceding claim in which the mesh comprises an interconnected

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    2018203187 08 May 2018 network of longitudinally extending rods or wires and transversely extending rods or wires defining openings, apertures, spaces, gaps or similar intermediate the interconnecting rods or wires,

    5 wherein the openings, apertures, spaces, gaps or similar are of a square or rectangular shape in the form of an open grid or similar.
32. 32. A workstation or method according to any preceding

    10 claim in which the mesh is a single sheet, a double sheet, or two or more interconnected sheets in which each sheet is substantially planar, wherein the mesh comprising a double sheet or two or more interconnected sheets further comprises spacers for

    15 interconnecting the two or more spaced apart planar sheets of mesh.
33. 33. A workstation or method according to any preceding claim in which the work station receives the

    20 reinforcement in a first direction which in one form is from a section of the manufacturing process for making the mesh, a mesh producing section or machine where the mesh is formed by welding individual rods or wires to each other to form the interconnected

    25 array of longitudinal and transverse rods, which manufacture occurs in a reinforcement manufacturing area or section.
34. 34. A workstation or method according to any preceding

    30 claim in which the first direction is in a direction from the mesh manufacturing area or section where the welding machine is located in a direction to the work station.
35. 35 35. A workstation or method according to any preceding claim in which the work station receives the frame assembly in a second direction, which is a direction

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    2018203187 08 May 2018 from the bridge assembly storage area or section of the layout of the manufacturing process.
36. 36. A workstation or method according to any preceding

    5 claim in which the first direction and the second direction are collinear but opposite directions to one another so that the workstation receives the reinforcement from a directly opposite side, to the side corresponding to the direction from where the 10 frame assembly is received.
37. 37. A workstation or method according to any preceding claim in which the work station moves the frame arrangement, together with attached reinforcement, in

    15 a third direction to exit the workstation.
38. 38. A workstation or method according to any preceding claim in which the third direction is perpendicular to the first and second collinear directions.
39. 39. A workstation or method according to any preceding claim in which the third direction is a combination of two or more directions including a combination of horizontal and vertical directions.
40. 40. A workstation or method according to any preceding claim in which the third direction is a single direction or a combination of two or more different directions .
41. 41. A workstation or method according to any preceding claim in which each framework module comprises a multitude of individual bridge bars, with each bridge bar having multiple engaging elements.
42. 42. A workstation or method according to any preceding claim in which the or each framework module has from

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    2018203187 08 May 2018 about two to about ten individual bridge bars, typically from about three to about eight individual bridge bars .

    5
43. 43. A workstation or method according to any preceding claim in which the individual bridge bars of the bridge assembly are releasably locked into position within the framework module using a clamp, clip, restraint, clasp, retainer or similar.
44. 44. A workstation or method according to any preceding claim in which the lock is a screw style clamp, a pin in hole arrangement, a spring clip or a spring clamp arrangement wherein the lock is releasable by being

    15 released by screwing, pinching, clamping, pushing, pulling or other suitable movement or combination of movements .
45. 45. A workstation or method according to any preceding

    20 claim in which during production of the reinforced panel, the frame arrangements and bridge assemblies are cleaned and waxed and the rods that are locked into place on the respective bridge bars move into a location from where the frame arrangement with

    25 attached bridge assemblies can be transferred to a bridge assembly storage area.
46. 46. A workstation or method according to any preceding claim in which the frame or the frame arrangement

    30 indexes from the location in preparation for the bridge assemblies being lifted or hoisted by a suitable lifting device, such as for example, a gantry robot or similar.

    35
47. 47. A workstation or method according to any preceding claim in which the lifting device in the form of a gantry robot manipulates the bridge assemblies to

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    2018203187 08 May 2018 ensure the bridge assembly is correctly set up and free of the gantry.
48. 48. A workstation or method according to any preceding

    5 claim in which if the bridge assemblies in the frame arrangement are detected as being of the correct type but located in incorrect positions, the gantry relocates the bridge assemblies to the correct positions along the framework.
49. 49. A workstation or method according to any preceding claim in which the frame or framework arrangement continues along the production line in the direction towards the workstation for engaging with the mesh.
50. 50. A workstation or method according to any preceding claim in which, if the bridge assemblies are of an incorrect type, the bridge assemblies are relocated to the bridge assembly storage area or similar, such

    20 as for example, to a storage magazine.
51. 51. A workstation or method according to any preceding claim in which rows of substantially identical bridge assemblies are stored in blocks or groups in

    25 preparation for subsequent selection and positioning in a future frame arrangement setup.
52. 52. A workstation or method according to any preceding claim in which correct bridges assemblies stored in

    30 the bridge assembly storage area are selected and moved from the magazine and are placed in the correct position on the frame module by the gantry robot.
53. 53. A workstation or method according to any preceding

    35 claim in which the layout within the manufacturing facility includes an interface wherein the interface is located between the mesh manufacturing area and

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    2018203187 08 May 2018 the bridge assembly storage area or storage magazine.
54. 54. A workstation or method according to any preceding claim further comprising an interface controller for

    5 controlling the matching of selected bridge assemblies with the selected mesh reinforcement so that the particular arrangement of the engaging elements of the bridge assembly are compatible with the particular mesh.
55. 55. A workstation or method according to any preceding claim in which the matching and/or selection of an individual bridge assembly with an individual mesh is computer controlled using an interface computer

    15 controller associated with both the manufacture and selection of the mesh and the selection of the bridge assembly, such that characteristics of the mesh to be manufactured are identified by the computer to enable a bridge assembly to be selected from the store of

    20 waiting bridge assemblies in the bridge assembly storage area, which selected bridge assembly has the correct characteristics, configuration, size, and the like to be compatible with the mesh selected from the mesh manufacturing area or mesh set up area prior to 25 actual manufacture.
56. 56. A workstation or method according to any preceding claim in which after selection of the bridge assembly from the bridge assembly storage area, the selected

    30 bridge assembly is positioned by the gantry robot into a framework in the correct position along the framework to create a frame arrangement that is matched to the mesh being manufactured.

    35
57. 57. A workstation or method according to any preceding claim in which the frame or framework arrangement once assembled is conveyed to the workstation to

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    2018203187 08 May 2018 arrive almost simultaneously with or shortly after or shortly before the arrival of the corresponding mesh reinforcement to enable the mesh to be secured to the frame arrangement for transfer to other areas or

    5 sections of the manufacturing process.
58. 58. A workstation or method according to any preceding claim in which the reinforcement is made in a reinforcement manufacturing station, area or section, 10 typically when the reinforcement is in the form of a mesh or similar, a mesh manufacturing station, area or section.
59. 59. A workstation or method according to any preceding

    15 claim in which the individual components of the mesh are welded together by a suitable welding machine system, wherein the welding machine system controls movement of empty frame arrangements at a suitable location within the overall production line, such as

    20 for example at, near or close to the bridge assembly storage area so that the particular bridge assemblies are matched to the particular mesh being produced by the welding machine system.

    25
60. 60. A workstation or method according to any preceding claim in which the control means controls the selection and movement of the required bridge assemblies, the correct mesh and the correct frame arrangement with correct bridge assemblies allowing

    30 simultaneous arrival at the work station for engagement to secure the mesh to the frame arrangement for further transport along or around the production line .

    35
61. 61. A workstation or method according to any preceding claim in which the number, position and/or orientation of the engaging elements attached to the

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    2018203187 08 May 2018 bridge bar corresponds to the size, shape and/or configuration of the reinforcement, particularly corresponding to the size and location of the openings or spaces within the mesh of the

    5 reinforcement so that the rods can be received through the spaces within the mesh to enable the rods to cooperatively engage with the mesh to secure the mesh to the rods, and hence to the bridge bar, and to the frame arrangement so that movement of the frame 10 arrangement also moves the reinforcement in unison with the frame arrangement to transfer the reinforcement from the work station as part of the overall manufacturing process for forming the product.
62. 62. A workstation or method according to any preceding claim in which the rods are pivotally mounted to the bridge bar allowing movement of the rods including rotational movement about the central axis of each

    20 individual rod to rotate that rod from an engaged position in which the rod is in contact with the mesh, and a release position enabling the rod to be removed from contact with the mesh to disengage from individual rods in the mesh, and hence from the

    25 product during the manufacturing process.
63. 63. A workstation or method according to any preceding claim in which the rod further comprises an engager for engaging the mesh wherein the engager includes a

    30 barb, arrow head or similar having a tapering or sloping surface for facilitating engagement and disengagement of the rod with the mesh.
64. 64. A workstation or method according to any preceding

    35 claim in which the engager is fixed or the engager is retractably movable to disengage the rod from the mesh.

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    2018203187 08 May 2018
65. 65. A workstation or method according to any preceding claim in which the selection of the correct bridge assembly, the selection of the correct position of

    5 the bridge assemblies in the frame arrangement, and/or the selection of the correct reinforcement are controlled by a controller.
66. 66. A workstation or method according to any preceding

    10 claim in which the controller is an interface controller, a computer-controlled interface controller wherein the controller is connected intermediate the mesh set up station or mesh manufacturing station and the bridge assembly storage

    15 area containing the various different forms of bridge assemblies having different configurations of groups of engaging elements .
67. 67. A method of transferring a reinforcement

    20 substantially as herein described with reference to the accompanying drawings .
68. 68. A method of transferring a reinforcement during a manufacturing operation substantially as herein

    25 described with reference to the accompanying drawings .
69. 69. A transfer line within a manufacturing facility for transferring a reinforcement from a work station

    30 during a manufacturing operation substantially as herein described with reference to the accompanying drawings .
70. 70. A workstation for securing a reinforcement and a

    35 frame arrangement to one another for enabling transfer of the reinforcement from the workstation during a manufacturing process substantially as

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    2018203187 08 May 2018 herein described with reference to the accompanying drawings .

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    FIG 4-1

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    FIG 6

    FIG 7

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    FIG 9