AU2020282946B2

AU2020282946B2 - Systems and methods for pre-plating structural members

Info

Publication number: AU2020282946B2
Application number: AU2020282946A
Authority: AU
Inventors: Chris Scot ANNIN; Michael Patrick BAKER; Shane Christopher Dittrich; Anthony Wayne FOSTER; Jeffrey Michael Hill; Anthony Edward Lancaster; Cole Jay LOGEMANN; Kristopher Ryan Okelberry
Original assignee: Builders Firstsource Inc
Current assignee: Builders Firstsource Inc
Priority date: 2019-05-31
Filing date: 2020-05-19
Publication date: 2026-02-19
Anticipated expiration: 2040-05-19
Also published as: WO2020242841A1; US20240375295A1; US11541553B2; EP3976321A1; CA3141569A1; US20230173690A1; US11986951B2; AU2020282946A1; EP3976321A4; AU2026200773A1; US20200376685A1

Abstract

Pre-plating systems and related methods are disclosed. A pre-plating system includes a press, an infeed robot configured to deliver a structural member to the press, and an outfeed robot configured to remove the structural member from the press. The press is configured to secure a plate to the structural member while the structural member is held in position by at least one of the infeed robot or the outfeed robot. A pre-plating system includes a press, a transfer pedestal, a plate picking robot, and a press loading robot. The plate picking robot is configured to pick a plate from a container and position the plate on the transfer pedestal. The press loading robot is configured to transfer the plate to the press. The press is configured to press the plate into a structural member positioned within the press.

Description

SYSTEMS AND METHODS FOR PRE-PLATING STRUCTURAL MEMBERS RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 62/855,179, entitled SYSTEMS AND METHODS FOR PRE-PLATING 2020282946

STRUCTURAL MEMBERS, filed May 31, 2019, which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

[0002] The present disclosure relates to pre-fabrication of structures and/or structural components for building structures, and more specifically to pre-plating structural members.

BACKGROUND

[0003] In constructing trusses, plates (e.g., nail plates) are used at joints between truss members to increase the strength of trusses. A plate may include teeth on a side of the plate that contacts the truss members to enable the plate to be coupled to the truss members by pressing the teeth into the truss members.

SUMMARY OF INVENTION

[0003a] According to one aspect, there is provided a pre-plating system, comprising a press, an infeed robot configured to deliver a structural member to the press, an outfeed robot configured to remove the structural member from the press, a transfer pedestal, a plate picking robot configured to retrieve a plate on the transfer pedestal, and a press loading robot configured to transfer the plate to the press, wherein the press is configured to secure the plate to the structural member while the structural member is held in position by at least one of the infeed robot or the outfeed robot.

[0003b] According to another aspect, there is provided a method of pre-plating a structural member, the method comprising delivering a structural member to an infeed robot, picking a plate from a container, delivering the plate to a transfer pedestal, providing a plate to a press, wherein providing the plate to the press comprises transferring the plate from the transfer pedestal to the press, positioning the structural member within the press based on one of an end of the structural member or a centroid of the structural member and pressing the plate into the structural member.

[0003c] According to a further aspect, there is provided a pre-plating system, comprising a press, a transfer pedestal, a plate picking robot configured to pick a plate from a container and position the plate on the transfer pedestal and a press loading robot configured to transfer the plate to the press, wherein the press is configured to press the plate into a structural member positioned within the press.

[0003d] Further aspects and/or features of the present invention will become apparent from 2020282946

the following detailed description.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0004] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0005] FIG. 1 is a perspective view of a pre-plating system, according to some embodiments.

[0006] FIG. 2 is a flowchart illustrating a method of operating the pre-plating system, according to some embodiments.

[0007] FIG. 3 is a perspective view of the pre-plating system delivering a structural member to an infeed robot.

[0008] FIG. 4 is a perspective view of the pre-plating securing a truss member with the infeed robot.

[0009] FIG. 5 is a perspective view of a portion of the pre-plating system picking a plate.

[0010] FIG. 6 is a perspective view of a portion of the pre-plating system placing a plate on a transfer pedestal.

1a

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[0011] FIG. 7 is a perspective view of the pre-plating system positioning a structural

member within a press.

[0012] FIG. 8 is a perspective view of the pre-plating system transferring a plate to the

press.

[0013] FIG. 9 is a perspective view of the pre-plating system pressing the plate into the

structural member.

[0014] FIG. 10 is a perspective view of the pre-plating system pressing another plate into

the structural member at a different location from the plate.

[0015] FIG. 11 is a perspective view of the pre-plating system transferring the structural

member to an outfeed robot.

[0016] FIG. 12 is a perspective view of the pre-plating system repositioning the structural

member within the press using the outfeed robot.

[0017] FIG. 13 is a perspective view of the pre-plating system delivering the truss member

to an outfeed delivery system.

[0018] FIG. 14 is a perspective view of the pre-plating system carrying the structural

member away from the pre-plating system.

[0019] FIG. 15 is a block diagram of a pre-plating system, according to some

embodiments.

[0020] FIG. 16 is a partially exploded perspective view of a universal gripper, according to

some embodiments.

[0021] FIG. 17 is a perspective view of an example of the universal gripper of FIG. 16

gripping a plate, according to some embodiments.

[0022] FIG. 18 is a front view of an example of a plate, according to some embodiments.

[0023] FIGS. 19A-19D illustrate example gripper fingers that may be used by the universal

gripper of FIG. 16.

DETAILED DESCRIPTION

[0024] In the following detailed description, reference is made to the drawings. In some

instances, like reference numerals are used in the various drawings to indicate similar

elements.

[0025] As used herein, the term "plate" refers to a plate to be used at a joint between

structural members. In some instances, a "plate" includes teeth for pressing into structural

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members and/or nail holes to enable nails to be driven through the plate to secure the plate

to the structural member.

[0026] As used herein, the term "structural member" refers to a member to be used to

construct a structure such as a building or other structure. For example, a structural member

may be used to construct a truss, which in turn may serve in construction of homes, other

buildings, bridges, or other structures. In such examples, a structural member may include a

truss member.

[0027] Embodiments disclosed herein relate to pre-plating structural members (e.g.,

boards) to be used in constructing structures such as homes or other buildings. Although

embodiments disclosed herein find particular utility in pre-plating truss members to be used

in constructing trusses, it will be apparent to those of ordinary skill in the art that

embodiments of the present disclosure encompass pre-plating of any structural members that

are intended for use in constructing any type of structure.

[0028] FIG. 1 is a perspective view of a pre-plating system 100, according to some

embodiments. The pre-plating system 100 includes a plate picking robot 110, a transfer

pedestal 114, a press loading robot 126, a press 116, an infeed delivery system 108, an

infeed robot 106, an outfeed robot 120, and an outfeed delivery system 122. The plate

picking robot 110 is configured to pick, from one of a plurality of containers 124, a plate

112 to be used at a joint between two or more truss members. The containers 124 are

configured to store the plates 112. The plate picking robot 110 is configured to place the

plate 112 on the transfer pedestal 114. The press loading robot 126 is configured to transfer

the plate 112 from the transfer pedestal 114 to a press surface 118 of the press 116. The

infeed delivery system 108 is configured to deliver a structural member 102 to the infeed

robot 106. The infeed robot 106 is configured to deliver the structural member 102 to the

press 116. The outfeed robot 120 is configured to remove the structural member 102 from

the press 116. The press 116 is configured to secure the plate to the structural member 102

(e.g., by pressing teeth of the plate into the structural member 102) while the structural

member 102 is held in position by either the infeed robot 106 or the outfeed robot 120.

[0029] The infeed robot 106 and the outfeed robot 120 are configured to position the

structural member 102 within the press 116 based on a determined centroid of the structural

member. The infeed robot 106 and the outfeed robot 120 can position the structural member

102 within the press 116 without the use of an indicia provided on or in the structural

member. As used herein, the term "centroid" refers to an average position of points in space

defining a structural member. In some embodiments, the centroid is determined based on a

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major plane of a truss member (e.g., an estimate of the average position of the points making

up the major plane). A location of the centroid of the structural member 102 may be

determined by various methods. For example, it may be known that the structural member

102 has a certain predetermined geometry (e.g., a 2x4, a 2x12, etc.), and that the infeed

delivery system 108 will deliver the structural member 102 to a known position and

orientation. As a specific example, the structural member 102 may have a known geometry,

and the infeed delivery system 108 may be configured to convey a leading edge of the

structural member 102 to a pre-determined location, allowing the infeed robot 106 to

estimate the location of the centroid relative to itself based on the known geometry and the

known position of the leading edge. As another example, image sensors may be used to

determine locations of edges and/or corners of the structural member 102, and an estimate of

the centroid may be determined based on the determined locations of the edges and/or

corners. A further example of determining the location of the centroid includes the use of

weight and/or mass measuring devices. Assuming that the truss member is approximately

uniformly dense, the centroid may be determined by locating the center of mass of the

structural member 102.

[0030] In some embodiments, one or more of the infeed robot 106, the outfeed robot 120,

the plate picking robot 110, or the press loading robot 126 may include robot arm assemblies

having securing mechanisms at their ends and one or more joints. The securing mechanisms

at the ends of the infeed robot 106 and the outfeed robot 120 are configured to secure the

structural member 102. By way of non-limiting example, the securing mechanisms at the

ends of the infeed robot 106 and the outfeed robot 120 may include a suction mechanism

(e.g., a vacuum system) configured to secure the structural member 102 thereto using

suction. Also by way of non-limiting example, the securing mechanisms at the ends of the

infeed robot 106 and the outfeed robot 120 may include a gripping mechanism (e.g., a claw)

to grip the structural member 102. As a further non-limiting example, the securing

mechanisms at the ends of the infeed robot 106 and the outfeed robot 120 may include

puncturing mechanisms configured to pierce the structural member 102. In some

embodiments the infeed robot 106 and the outfeed robot 120 may include both a suction

mechanism and a gripping mechanism at the end thereof. In some such embodiments the

suction mechanism may be used to secure structural members that are longer than a

predetermined threshold length (e.g., four feet), and the gripping mechanism may be used to

grip structural members that are shorter than the predetermined threshold length.

[0031] The securing mechanisms at the ends of the plate picking robot 110 and the press

loading robot 126 are configured to secure the plates 112. By way of non-limiting example,

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the securing mechanisms at the ends of the plate picking robot 110 and the press loading

robot 126 may include a magnet (e.g., a passive magnet and/or an electromagnet) to secure

plates 112 including magnetically attractive materials (e.g., iron, nickel, etc.). Magnets may

also be used at the transfer pedestal 114 and/or the press 116 to secure the plates thereto. In

instances where handoffs of the plate between devices having passive magnets occur, a

device handing off the plate to a subsequent device may roll away from the plate rather than

back straight off the plate to facilitate detachment from the plate without interrupting the

coupling between the plate and the subsequent device. Another approach may be to use

weaker magnets in devices than stronger magnets used in subsequent device (e.g., magnets

of the plate picking robot 110, the transfer pedestal 114, the press loading robot 126, and the

press 116 have successively stronger magnets to facilitate handoffs between devices). In

instances where electromagnets are used, the electromagnets may be controlled to facilitate

handoffs between the various devices. For example, the plate picking robot 110 may

maintain current flowing through an electromagnet at the end thereof to secure the plate to

the end of the plate picking robot 110, then interrupt the current flowing therethrough while

initiating a current to an electromagnet of the transfer pedestal 114. Also by way of non-

limiting example, the securing mechanisms at the ends of the plate picking robot 110 and the

press loading robot 126 may include gripping members to grip the plates 112.

[0032] In some embodiments the securing mechanisms at the ends of the plate picking

robot 110 and the press loading robot 126 may include a gripping mechanism. For example,

the plate picking robot 110 and/or the press loading robot 126 may include a universal

gripping mechanism similar to that discussed below with reference to FIGS. 16-19D. This

universal gripping mechanism is configured to grip the plate regardless of the pattern of

teeth/holes on the plate, as will be discussed in more detail below.

[0033] The one or more joints of the infeed robot 106, the outfeed robot 120, the plate

picking robot 110, and the press loading robot 126 are configured to enable the infeed robot

106, the outfeed robot 120, the plate picking robot 110, and the press loading robot 126 with

motion capabilities (e.g., translational motion, rotary motion). These joints may include

linear joints, orthogonal joints, rotational joints, twisting joints, revolving joints, or

combinations thereof. In the embodiment illustrated in FIG. 1 the plate picking robot 110 is

mounted on a trolley 130 that traverses a track 132 that extends between multi-tiered

container racks 128 loaded with containers 124 filled with plates 112 of various shapes

and/or sizes. The containers 124 are located within reach of the plate picking robot 110 to

enable the plate picking robot 110 to retrieve plates 112 from the containers 124. The joints

of the plate picking robot 110 enable the plate picking robot 110 to reach plates 112 located

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within any of the containers 124. The plates 112 may be organized into specific locations

within the container racks 128 and containers 124 SO that the plate picking robot 110 can

traverse the track to the location of a certain one of the containers 124 and pick the proper

plate therefrom. The plate picking robot 110 then, if needed, traverses the track 132 to

within reach of the transfer pedestal 114 and places the plate on the transfer pedestal 114.

The plates 112 may be organized by size and/or shape within the containers 124 SO that the

plate picking robot 110 can retrieve a plate of a desired shape and/or size from a known

location.

[0034] In some embodiments the plate picking robot 110 is configured to rotate a retrieved

plate to a desired orientation before placing the plate on the transfer pedestal 114.

Accordingly, it may be desirable to secure the plate with the securing mechanism at the end

of the plate picking robot 110 at a center of the plate to enable balanced rotation of the plate.

A center of the plate may be located based on known geometries of the plate and the

containers 124 that hold the plates 112, and known positions of the containers 124 relative

to the plate picking robot 110. With the plate placed on the transfer pedestal 114 at a desired

angle, the press loading robot 126 can transfer the plate from the transfer pedestal 114 to the

press 116 without undue rotation. It should be noted that in some embodiments the transfer

pedestal 114 may be used to rotate the plate to the desired angle instead of, or in addition to,

the plate picking robot 110.

[0035] The joints of the press loading robot 126 enable the securing mechanism at the end

of the press loading robot 126 to extend between the transfer pedestal 114 and the press

surface 118 of the press 116.

[0036] The joints of the infeed robot 106 enable the securing mechanism at the end of the

infeed robot 106 to extend between the infeed delivery system 108 and the press 116. These

joints may also enable the infeed robot 106 to position the structural member 102 in various

different positions within the press 116 to enable plates 112 to be applied to various

locations on the structural member 102.

[0037] Similarly, the joints of the outfeed robot 120 enable the securing mechanism at the

end of the outfeed robot 120 to extend between the press 116 and the outfeed delivery

system 122. These joints may also enable the outfeed robot 120 to position the structural

member 102 in various different positions within the press 116 to enable plates 112 to be

applied to various locations on the structural member 102.

[0038] The press 116 may include an electrically controllable press As previously

discussed, in some embodiments the press 116 may include a magnet (e.g., an electromagnet

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configured to selectively secure a plate to the press surface 118) in a position and orientation

in which the press loading robot 126 delivered the plate thereto). The press 116 is

configured to apply sufficient force to a plate mounted thereto to press the plate into the

structural member 102.

[0039] In some embodiments the transfer pedestal 114 includes a working surface 104. In

the embodiment illustrated in FIG. 1, the working surface 104 of the transfer pedestal 114 is

at a slant rather than being oriented horizontally. The working surface 104, however, may

have any orientation including horizontal, vertical, or any non-horizontal and/or non-vertical

slopes. In some embodiments, the transfer pedestal 114 may include a magnet (e.g., an

electromagnet that is selectively controllable) to enable a plate to be secured thereto. As

previously discussed, orientation of the plate in anticipation of placing the plate at a

particular orientation on the structural member 102 may be performed at least in part by

orienting the plate in a specific way, by the plate picking robot 110, on the working surface

104 of the transfer pedestal 114.

[0040] In some embodiments the infeed delivery system 108 may include a conveyer

system, such as that illustrated in FIG. 1. In some embodiments, the conveyer system may

be tilted at a non-horizontal slope to present the structural member 102 to the infeed robot

106 in a convenient orientation for the infeed robot 106 to secure the structural member 102.

In other words, it may be convenient for the infeed robot 106 to secure the structural

member 102 if it approaches the infeed robot 106 at a non-horizontal angle. In some

embodiments, however, the conveyer system may be oriented horizontally.

[0041] In some embodiments the outfeed delivery system 122 includes one or more trolleys

134 that traverse one or more tracks 136. The trolleys 134 may be configured to secure the

pre-plated structural member 102 thereto and move along the tracks 136 to carry the

structural member 102 away from the pre-plating system 100. By way of non-limiting

example, the trolleys 134 may include electromagnets configured to secure to one or more

metal plates pressed into the structural member 102. Also by way of non-limiting example,

the trolleys 134 may include suction mechanisms to enable the trolleys 134 to secure to the

structural member 102 using suction. In some embodiments the outfeed delivery system 122

is configured to deliver the structural member 102 to a truss assembly system (e.g., an

automatic truss assembly systems) where the structural member 102 will be used along with

other truss members to build a truss.

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[0042] The structural member 102 may in some embodiments include a truss member. In

some embodiments, the structural member 102 may include a wooden board, a metal

member, or a member of another material that is suitable for structural support of a building.

[0043] FIG. 2 is a flowchart illustrating a method 200 of operating the pre-plating system

100 of FIG. 1, according to some embodiments. FIGS. 3, 4, and 7-14 are perspective views

of the pre-plating system 100 of FIG. 1, illustrating various acts 202, 204, and 210-218 of

the method 200 of FIG. 2. FIGS. 5 and 6 are perspective views of portions 500, 600,

respectively, of the pre-plating system 100 of FIG. 2, illustrating acts 206, 208 of the

method 200 of FIG. 2.

[0044] Referring to FIGS. 2 and 3 together, the method 200 includes delivering 202 the

structural member 102 to the infeed robot 106 with the infeed delivery system 108. In some

embodiments delivering 202 the structural member 102 to the infeed robot 106 includes

conveying the structural member 102 to the infeed robot 106 using a conveyer system. In

some embodiments delivering 202 the structural member 102 to the infeed robot 106

includes delivering the structural member 102 to the infeed robot 106 with a major plane of

the structural member 102 oriented in a tilted, non-horizontal angle to enable the infeed

robot 106 to conveniently secure the structural member 102.

[0045] Referring now to FIGS. 2 and 4, the method 200 also includes securing 204 the

structural member 102 with the infeed robot 106. FIG. 4 illustrates the infeed robot 106

securing 204 the structural member 102 with the securing mechanism at the end of the

infeed robot 106. In some embodiments, securing the structural member 102 with the infeed

robot 106 includes suctioning the structural member to the infeed robot 106 with a vacuum

system. In some embodiments, securing the structural member 102 to the infeed robot 106

includes gripping the structural member 102 with a gripping member at the end of the infeed

robot 106.

[0046] FIG. 5 is a perspective view of a portion 500 of the pre-plating system 100 of FIG.

1. Referring to FIGS. 2 and 5 together, the method 200 further includes picking 206 a plate

from one of the containers 124 with the plate picking robot 110. FIG. 5 shows the plate

picking robot 110 picking 206 a plate from one of the containers 124. In some embodiments,

picking 206 a plate includes securing a center of the plate to an end of the plate picking

robot 110. In some embodiments, picking 206 a plate includes securing the plate to the end

of the plate picking robot 110 with a gripping mechanism. In some embodiments, picking

206 a plate includes securing the plate to the end of the plate picking robot 110 with a

magnet (e.g., a passive magnet, an electromagnet, or both).

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[0047] FIG. 6 is a perspective view of a portion 600 of the pre-plating system 100 of FIG.

1. Referring now to FIGS. 2 and 6 together, the method 200 also includes placing 208 a

plate 602 on the transfer pedestal 114 with the plate picking robot 110. FIG. 6 shows the

plate picking robot 110 placing 208 the plate 602 on a working surface 104 of the transfer

pedestal 114. In some embodiments, placing 208 a plate 602 on the transfer pedestal 114

comprises rotating the plate 602 to a desired orientation using the plate picking robot 110

and placing the plate 602 on the transfer pedestal 114 in the desired orientation.

[0048] Referring now to FIGS. 2 and 7, the method 200 further includes positioning 210

the structural member 102 within the press 116 with the infeed robot 106. FIG. 7 illustrates

the infeed robot 106 positioning 210 the structural member 102 within the press 116. In

some embodiments, positioning 210 the structural member 102 within the press 116 includes

positioning the structural member 102 within the press 116 based on a determined centroid

of the structural member 102. In some embodiments, positioning 210 the structural member

102 within the press 116 includes positioning the structural member within the press 116

without the use of an indicia provided on or in the structural member 102.

[0049] In some embodiments, the positioning 210 of the structural member 102 within the

press 116 may be accomplished by approaching the press from above and gradually

lowering the structural member 102 downward into the press 116 to be engaged by the press

surface. Stated otherwise, the structural member 102 can be lowered in a downward

direction D (indicated in FIG. 7 by arrow D) that is transverse to the length of the structural

member 102 as shown in FIG. 7 and toward the floor.

[0050] In some embodiments, a vision system 140 may scan the structural member 102 at

positioning 210 into the press 116. For example, the vision system 140 may scan the

structural member 102 as it is lowered in the downward direction D (or otherwise inserted or

placed) into the press 116. As another example, the infeed robot 106 may bring the

structural member 102 to a fixed position in front of the vision system 140 for scanning

prior to placement of the structural member 102 into the press 116. The vision system 140

can identify a bottom or lowest edge of the structural member 102, which can be used as a

reference for appropriately positioning the structural member 102 in the press 116. The

vision system 140 can identify a bottom edge of the structural member 102 and detect droop

or sag in the robotic arm and/or inject the location of the bottom edge as an input into the

infeed robot 106 (and/or the outfeed robot 120 to enhance or otherwise improve preciseness

of positioning of the structural member 102 in the press 116. A backdrop may also be

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provided in the field of view of the vision system 140 and behind the structural member 102

to facilitate capture of image data by the vision system 140.

[0051] In other embodiments, the positioning 210 of the structural member 102 within the

press 116 may be accomplished by approaching the press from a side or in a lateral direction

L (indicated in FIG. 7 by arrow L). In still other embodiment, insertion of the structural

member 102 into the press 116 may be approached from another direction, such as a

combination of a lateral direction L and a downward direction D.

[0052] Referring now to FIGS. 2 and 8 together, the method 200 includes transferring 212

the plate 602 from the transfer pedestal 114 to a press surface 118 of the press 116. FIG. 8

illustrates the press loading robot 126 placing the plate 602 on the press surface 118 of the

press 116. In some embodiments, transferring 212 the plate 602 from the transfer pedestal

114 to a press surface 118 of the press 116 includes securing the plate 602 on the press

surface 118 while at least one of the infeed robot 106 or the outfeed robot 120 positions the

structural member 102 within the press 116. In some embodiments, transferring 212 the

plate 602 from the transfer pedestal 114 to a press surface 118 of the press 116 includes

securing the plate on the press surface 118 using a securement mechanism 119, such as a

magnet (e.g., a passive magnet, an electromagnet, or both), a vacuum, a mechanical gripper,

or the like. The securement mechanism 119 may be internal to and/or otherwise integrated

with the press surface 118 of the press 116.

[0053] Referring to FIGS. 2 and 9, the method 200 includes pressing 214 the plate 602 into

the structural member 102 with the press 116. FIG. 9 illustrates the press 116 pressing 214

the plate 602 into the structural member 102.

[0054] Referring now to FIGS. 2 and 10 together, in some embodiments, positioning 210

and pressing 214 comprises repositioning the structural member 102 within the press 116

and pressing another plate into the structural member 102 at a different location than that of

the plate 602. FIG. 10 illustrates the infeed robot 106 holding the structural member 102 in

another position and the press 116 pressing another plate into the structural member 102 at a

different location from that of the plate 602.

[0055] Referring to FIGS. 2 and 11 together, the method 200 also includes transferring 216

the structural member 102 from the infeed robot 106 to an outfeed robot 120. FIG. 11

illustrates the infeed robot 106 handing off the structural member 102 to the outfeed robot

120. In some embodiments there may be a sequence in which the press 116 holds the

structural member 102 while the infeed robot 106 and/or the outfeed robot 120 exchange or

sequentially secure the structural member 102 (e.g., the infeed robot 106 may release the

10

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structural member 102 while the press 116 holds the structural member 102 and the outfeed

robot 120 may secure the structural member 102 before the press 116 releases the structural

member 102.

[0056] FIG. 11 also illustrates the plate picking robot 110 placing another plate 1102 on

the transfer pedestal 114. The other plate 1102 is transferred from the transfer pedestal 114

to the press surface 118 of the press 116, as discussed above with reference to FIG. 8 and

transferring 212.

[0057] FIG. 12 illustrates the outfeed robot 120 positioning the structural member 102

within the press 116 while the press 116 presses the other plate 1102 into the structural

member 102.

[0058] Referring now to FIGS. 2 and 13, the method 200 further includes delivering 218

the structural member 102 carrying the plate 602 and the other plate 1102 to an outfeed

delivery system 122 configured to carry the structural member 102 from the pre-plating

system 100.

[0059] FIG. 14 illustrates the outfeed delivery system 122 carrying the structural member

102 away from the pre-plating system 100. The outfeed delivery system 122 may transport

the now pre-plated structural member 102 to an assembly system (e.g., an assembly table on

which a structural component may be assembled by joining multiple structural members.

[0060] FIG. 15 is a block diagram of the pre-plating system 100 of FIG. 1, according to

some embodiments. The pre-plating system 100 includes the infeed robot 106, the infeed

delivery system 108, the plate picking robot 110, the transfer pedestal 114, the press 116,

the outfeed robot 120, the outfeed delivery system 122, and the press loading robot 126, as

discussed above. The pre-plating system 100 also includes at least one controller 1502 and

one or more drive systems 1508. The controller 1502 may include a central processing unit

(CPU), a microcontroller, a programmable logic controller (PLC), a field programmable gate

array (FPGA), other programmable device, or combinations thereof. The controller 1502 is

configured to control one or more aspect of operation of one or more of the infeed robot

106, the infeed delivery system 108, the plate picking robot 110, the transfer pedestal 114,

the press 116, the outfeed robot 120, the outfeed delivery system 122, and the press loading

robot 126, or the drive systems 1508 according to embodiments discussed above. For

example, the controller 1502 may be configured to at least partially control motion of one or

more of the infeed robot 106, the plate picking robot 110, the press loading robot 126, or the

outfeed robot 120. Also, the controller 1502 may be configured to at least partially control

the infeed delivery system 108 and/or the outfeed delivery system 122. The controller 1502

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may, in some embodiments, be configured to control electromagnets of the transfer pedestal

114 and/or the press 116. The controller 1502 may also be configured to control the press

116.

[0061] In some embodiments, the controller 1502 includes one or more processors 1504

and one or more data storage devices 1506 (hereinafter referred to as "storage" 1506). The

storage 1506 may include nonvolatile storage (e.g., Flash memory, a hard disc drive, a solid

state drive, etc.), volatile storage (e.g., random access memory (RAM), etc.) or combinations

thereof. The storage 1506 may, in some embodiments, include computer-readable

instructions stored thereon. The computer-readable instructions are configured to instruct the

processors 1504 to perform control the infeed robot 106, the infeed delivery system 108, the

plate picking robot 110, the transfer pedestal 114, the press 116, the outfeed robot 120, the

outfeed delivery system 122, or the press loading robot 126 according to one or more

operations discussed above.

[0062] The storage 1506 may also be configured to store information that is useful for

operating the pre-plating system 100. For example, the storage 1506 may be configured to

store information relating to geometries and/or positions of various components of the pre-

plating system 100 to enable the controller 1502 to determine a position of a centroid of the

structural member 102, a position of a center of a plate 602, a location of the press 116, and

other such information.

[0063] The drive systems 1508 are configured to drive mechanical motion or other

operation of one or more of the infeed robot 106, the infeed delivery system 108, the plate

picking robot 110 the transfer pedestal 114, the press 116, the outfeed robot 120, the outfeed

delivery system 122, or the press loading robot 126 according to embodiments discussed

above. For example, the drive systems 1508 may include an electrical drive system, a

pneumatic drive system, a hydraulic drive system, a combustion engine system, other drive

systems, or combinations thereof. In some embodiments the controller 1502 may be

configured to control the drive systems 1508.

[0064] FIG. 16 is a partially exploded perspective view of a universal gripper 1600,

according to some embodiments. The universal gripper 1600 is configured to grip teeth of a

plate using a set of gripper fingers 1602 that are designed to match a pattern of teeth on a

given plate. The gripper fingers 1602 may be interchanged with other gripper finger sets that

match the patterns of different plates having different teeth patterns. For example, different

manufacturers of plates may use different teeth patterns. As a result, the universal gripper

1600 may be configured to grip any plate having any teeth pattern using interchangeable

WO wo 2020/242841 PCT/US2020/033664

gripper fingers (e.g., the gripper fingers 1602). As a specific, non-limiting example, the

gripper fingers 1602 of FIG. 16 were designed to match plates with a teeth pattern including

oscillating positions of the teeth on the plates and based on the assumption that the tooth in

the top left corner of a gripper coverage area (gripper coverage area 1802 from FIG. 18) is

always in the high position relative to the row it is in. An example of such a plate is

discussed below with reference to FIG. 18.

[0065] FIG. 17 is a perspective view of an example of the universal gripper 1600 of FIG.

16 gripping a plate 1800, according to some embodiments. The universal gripper 1600 may

use compressed air to actuate a cylinder to close around the gripper fingers 1602 of the nail

plate. A sensor detects if a nail plate is present and, if it is, the sensor may also detect that

the nail plate is in a correct position. In some embodiments, the sensor may also detect an

orientation (e.g., direction of nails) of a nail plate. Upon the gripper fingers 1602 closing

around the nail plate, another sensor may detect that the nail plate was engaged and/or that

the nail plate was slid up out of the fixture.

[0066] FIG. 18 is a front view of an example of a plate 1800, according to some

embodiments. The plate 1800 of FIG. 18 includes a teeth pattern of rows of holes/teeth, each

row having oscillating positions of holes/teeth. A gripper coverage area 1802 and a center

1804 of the plate 1800 are also shown in FIG. 18. In some embodiments, the universal

gripper 1600 may position itself according to the gripper coverage area 1802 based on the

center 1804 of the plate 1800.

[0067] FIGS. 19A-19D illustrate example gripper fingers 1900 that may be used by the

universal gripper 1600 of FIG. 16. The example gripper fingers 1900 include an oscillating

gripper finger 1902, a constant depth gripper finger 1904, a flat gripper finger 1906, and a

flat notch gripper finger 1908. The oscillating gripper finger 1902 is similar to the gripper

fingers 1602 discussed above with reference to FIG. 16. As previously discussed, the

oscillating gripper finger 1902 was designed to match plates with a teeth pattern including

always in the high position relative to the row it is in. The assumption that the tooth in the

top left corner of the gripper coverage area, however, is not always true. As a result, the

constant depth gripper finger 1904 may be used regardless of whether the tooth in the top

left corner of the gripper coverage area is in the high position or low position relative to the

row it is in. The flat gripper finger 1906 and the flat notch gripper finger 1908 are other

examples of gripper fingers that may be used by the universal gripper 1600.

[0068] It will be apparent to those having ordinary skill that many embodiments, though not expressly discussed herein, may exist that fall within the scope of the present disclosure.

[0069] In this specification, the terms “comprise”, “comprises”, “comprising” or similar terms are intended to mean a non-exclusive inclusion, such that a system, method or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed. 2020282946

Claims

2020282946 04 Jun 2024 CLAIMS CLAIMS What is claimed is:

1. A pre-plating system, comprising: a press; an infeed robot configured to deliver a structural member to the press; 2020282946

an outfeed robot configured to remove the structural member from the press; a transfer pedestal; a plate picking robot configured to retrieve a plate on the transfer pedestal; and a press loading robot configured to transfer the plate to the press, wherein the press is configured to secure the plate to the structural member while the structural member is held in position by at least one of the infeed robot or the outfeed robot.

2. The pre-plating system of claim 1, wherein the at least one of the infeed robot or the outfeed robot is configured to position the structural member within the press based on one of an end of the structural member or a determined centroid of the structural member.

3. The pre-plating system of claim 2, wherein the at least one of the infeed robot or the outfeed robot is configured to position the structural member within the press without the use of an indicia provided on or in the structural member.

4. The pre-plating system of claim 2 or 3, wherein the one of the end or the centroid is determined based on a known geometry of an infeed delivery system configured to deliver the structural member to the infeed robot and a known geometry of the structural member.

5. The pre-plating system of any preceding claim, wherein the press is configured to secure the plate on a press surface of the press while the at least one of the infeed robot or the outfeed robot positions the structural member within the press.

6. The pre-plating system of claim 5, wherein the press includes a securement mechanism configured to secure the plate on the press surface.

7. The pre-plating system of any preceding claim, further comprising an infeed delivery system configured to deliver the structural member to the infeed robot.

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8. The pre-plating system of any preceding claim, further comprising an outfeed delivery 04 Jun 2024 2020282946 04 Jun 2024

system configured to deliver the structural member having the plate secured thereto from the outfeed robot. outfeed robot.

9. The pre-plating system of any preceding claim, wherein at least one of the infeed robot or the outfeed robot includes both a suction mechanism and a gripping mechanism, wherein the at least one of the infeed robot or the outfeed robot is configured to secure the structural 2020282946

member with: the suction mechanism if the structural member is longer than a predetermined threshold length, and the gripping mechanism if the structural member is shorter than the predetermined threshold length.

10. A method of pre-plating a structural member, the method comprising: delivering a structural member to an infeed robot; picking a plate from a container; delivering the plate to a transfer pedestal; providing a plate to a press, wherein providing the plate to the press comprises transferring the plate from the transfer pedestal to the press; positioning the structural member within the press based on one of an end of the structural member or a centroid of the structural member; and pressing the plate into the structural member.

11. The method of claim 10, further comprising securing the plate to the transfer pedestal using a magnet.

12. The method of claim 10 or 11, wherein picking the plate from a container and delivering the plate to a transfer pedestal comprises picking and delivering the plate using a picking robot.

13. The method of claim 10, 11 or 12, wherein transferring the plate from the transfer pedestal to the press comprises transferring the plate from the transfer pedestal to the press with a press loading robot.

14. A pre-plating system, comprising: a press; a transfer pedestal;

16 a plate picking robot configured to pick a plate from a container and position the 04 Jun 2024 2020282946 04 Jun 2024 plate on the transfer pedestal; and a press loading robot configured to transfer the plate to the press, wherein the press is configured to press the plate into a structural member positioned within the press.

15. The pre-plating system of claim 14, wherein the plate picking robot is configured to secure the plate at a center of the plate. 2020282946

16. The pre-plating system of claim 15, wherein the plate picking robot is configured to locate the center of the plate based on a known location of the container and a known position of the center of the plate relative to the container.

17. The pre-plating system of any of claims 14 to 16, wherein the plate picking robot is configured to rotate the plate to place the plate at a desired orientation on the transfer pedestal.

18. The pre-plating system of any of claims 14 to 17, wherein the plate picking robot includes a gripping mechanism at an end thereof to grip the plate.

19. The pre-plating system of any of claims 14 to 18, wherein the plate picking robot and/or the press loading robot includes a magnet at an end thereof to couple to the plate.

20. The pre-plating system of claim 19, wherein the end of the press loading robot is configured to decouple the press loading robot from the plate upon positioning the plate on the press.

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