CA2235173A1 - Laser projection work station and method of manufacturing panel assemblies having configured openings - Google Patents
Laser projection work station and method of manufacturing panel assemblies having configured openings Download PDFInfo
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- CA2235173A1 CA2235173A1 CA 2235173 CA2235173A CA2235173A1 CA 2235173 A1 CA2235173 A1 CA 2235173A1 CA 2235173 CA2235173 CA 2235173 CA 2235173 A CA2235173 A CA 2235173A CA 2235173 A1 CA2235173 A1 CA 2235173A1
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Abstract
A laser projection work station and method of manufacturing a panel assembly, such as a floor assembly, having a plurality of configured openings atpredetermined locations from a plurality of panels using a laser projection system.
The method includes locating one or a plurality of panels opposite a scanning laser projector, projecting a laser image on the panel or panels which is a general outline of the openings to be cut in the panels at the predetermined location and oriented pursuant to a data set in the computer control. Openings are then cut in the panel using the laser generated outline as a template. Finally, the panels are assembled as required to form a floor assembly or other panel assembly. The laser projection work station included in a conveyor, preferably including rollers, which support the marginal edges of the panel for conveying the panel beneath a laser scanner. The laser projector is operably connected to a computer having a data set of the configuration and location of the openings to be cut in each of the panels.
The method includes locating one or a plurality of panels opposite a scanning laser projector, projecting a laser image on the panel or panels which is a general outline of the openings to be cut in the panels at the predetermined location and oriented pursuant to a data set in the computer control. Openings are then cut in the panel using the laser generated outline as a template. Finally, the panels are assembled as required to form a floor assembly or other panel assembly. The laser projection work station included in a conveyor, preferably including rollers, which support the marginal edges of the panel for conveying the panel beneath a laser scanner. The laser projector is operably connected to a computer having a data set of the configuration and location of the openings to be cut in each of the panels.
Description
CA 0223~173 1998-04-17 Expl_~s Mail #EM494000484US
LASER PRO~ECTION WORK STATION AND METHOD OF
MANUFACTURING PANEL ASSEMBLIES HAVING CONFIGURED
OPENINGS
The present invention relates to a laser projection work station and method of manufacturing a panel assembly, such as a floor assembly for a manufactured home, using a laser im~ging system. The method of this invention may also be used to form a configured opening, such as a circular opening, through a panel at 10 a precisely predetermined location using a laser im~ging system and work station.
More specifically, the present invention relates to a laser projection work station and method of manufacturing a panel assembly, wherein the configured openings are precisely located and oriented in the panels by projecting a laser image of the openings, cutting the openings and assembling the panels to form a floor panel 15 assembly or the like.
BACKGROUND OFTHEINVENTION
Laser imaging systems have been used for some years to assemble components of an assembly, such as the components of a truss or an aircraft 20 assembly. The laser im~ging system generally includes a computer or controller, a laser scanner projector and a data set defining the pattern of the components of the assembly in the desired location and pattern. The laser scanner includes a laser which is projected on mirrors rotatably mounted in parallel perpendicular relation.
The rapidly sc~nning laser image is actually a laser spot which moves from location 25 to location with sufficient speed to appear to the assembly person as a continuous line. A plurality of images may be projected essentially simultaneously for assembly of a plurality of components, such as the planks and/or the truss I
CA 0223~173 1998-04-17 A~orney Doc~etNo. 60,132~5 connector plates on a flat surface or the components of an aircraft on a three-dimensional work surface. Such laser assembly systems are available from Virtek Vision Corp., the assignee of the present invention.
Panel assemblies of the type presently used by the manufactured building 5 industry for floor assemblies comprise a plurality of wood or fiber panels which are assembled in co-planar abutting relation on floor joists generally by nailing and/or adhesively bonding the panels on the transverse joists. Configured openings are cut through the panels between the joists to receive plumbing or ductwork at a later time, generally following assembly of the walls to the floor. The configured 10 openings include circular openings which receive pipes, drains and the like and rectangular openings to receive rectangular metal ducts for example. Modern manufactured home facilities generally assemble the floor on a wheeled support, such as used for supporting railroad cars and the assembly is then moved through an assembly line as the home is manufactured.
Manufactured homes have several advantages over "stick built" homes including reduction in cost, particularly labor cost, and precision. Further, the home is not subject to the elements during manufacture because the home is built in an indoor manufacturing facility.
The method of cutting configured openings in the floor as presently 20 manufactured requires accurately measuring the required location, size and orientation of each opening from the side edges of each panel, marking the openings on the panels and cutting the openings as marked. Where the opening is rectangular, for example, the rectangular opening must also be oriented on the Attorney DocketNo. 60,132~45 panel before cutting. Manufactured homes are made to specifications, often as ordered by a customer. Thus, several designs of manufactured homes may be made at one time in a manufacturing facility. Thus, cutting of the configured openings in the floor assembly is time consuming, requires exact measurement by relatively S skilled technicians and is subject to errors which may not be discovered until later in the manufacturing process, when others are attempting to assembly the ductwork and plumbing. In some instances, this requires cutting new openings and patching the incorrectly located openings, sometimes after the finish flooring is in place.
Another problem is cutting circular openings in the panels using markings made on 10 the panel. When a hole cutter is placed on a circular marking, the marking is at least partially obscured by the cutter, making accurate location difficult.
The laser projection work station and method of this invention utilizes a laser im~ging system which eliminates the above described problems, particularly in the manufacturer of floor assemblies, by elimin~ting the requirement for 15 measurement and marking of the location of each opening through the floor panels, resulting in improved accuracy and reduced labor cost. The laser work station and method of this invention may be used to quickly and accurately locate and orient openings through floor panels and other panel assemblies and to accurately cut circular and rectangular openings, without marking.
SUMMARY OF THE INVENTION
As set forth above, the laser projection work station and method of this invention may be utilized to manufacture a panel assembly, such as a floor CA 0223~173 1998-04-17 AUorney D~ketNo. 60,132-045 assembly, having a plurality of configured openings at precise predetermined locations using a laser imaging system. The method includes locating each or a plurality of panels requiring a configured opening therethrough opposite a laserprojector and projecting a laser image at the predetermined locations on each of the S panels comprising a laser generated general outline of the configured openings. In a typical structural panel assembly, such as manufactured home floor assembly, the openings through the panels must also be oriented and located between the transverse floor joists or support members. The method then includes cutting the openings in the panel or panels requiring an opening therethrough using the laser 10 generated outline as a template and assembling the panels in generally co-planar relation to form a floor assembly or other panel assembly with the configured openings located at the predetermined locations between the transverse support members.
Where a circular opening is required having a predetermined diameter, for 15 example, the preferred method of this invention includes projecting a laser generated square outline on the floor panel having sides equal to the diameter of the circular opening at the predetermined location of the circular opening. Then, cutting the circular opening with an annular hole cutter, for example, using the laser generated square outline as a template. Where a rectangular opening is 20 required, the method includes generating a rectangular outline of the desired opening on the panel having the required orientation, then cutting the rectangular opening, using the laser generated outline as a template. This method assures both accurate positioning and orientation of the rectangular opening.
CA 0223~173 1998-04-17 Attorney D~ketNo. 60,132~45 Where the method of this invention is used to manufacture a floor assembly, which is a preferred embodiment of the method of this invention, the panels are assembled in generally co-planar abutting relation to a plurality of transverse joists, with the openings located between the joists. The panels may be attached to the 5 joists by conventional methods, including nailing the panels to the joists and/or adhesively bonding the panels to the joists. As will be understood by those skilled in the art of manufacturing floor assemblies, the joists may be prefabricated into a rectangular frame structure with the joists extending perpendicular to the support table and panel assembly. The joist may comprise wood or metal support members 10 having an edge face which is attached to the floor panels. The method of this invention may also be utilized to cut a circular opening in a single panel, wherein the preferred method includes projecting a square outline on the panel having sides equal to the diameter of the desired circular opening, then cutting the circular opening using the laser generated square outline as a template, wherein the center lS of each side of the laser outline extends tangentially to the circular opening.
The laser projection work station of this invention is particularly adapted to cutting configured openings in panels at predetermined locations and orientations using the method of this invention. The laser work station includes a conveyor for transferring a panel beneath a laser projector having a stop locating the panel 20 beneath the laser scanner or projector. The laser projector is mounted above the conveyor and the work station includes a computer having a data set of the shape, size, location and orientation of the openings to be cut in each of the panels. The computer is operably connected to a laser scanner which controls the laser scanner CA 0223~173 1998-04-17 Attorney DocketNo. 60,132~5 to project a laser outline of the laser template on each of the panels. In the preferred embodiment of the laser projection work station of this invention, theconveyor includes a plurality of spaced rollers supporting the opposed marginal edges of the panels having an axis of rotation generally parallel to the panel and the 5 rollers are spaced sufficiently to permit cutting of the configured openings in the panels between the rollers using the laser outline template. In the disclosed embodiment, the conveyor further includes opposed generally parallel rails which guide the panels beneath the laser scanner and in the preferred embodiment, the rails include laser position indicating elements and the computer controls the laser 10 scanner to periodically scan the laser positioning indicating elements to accurately locate the laser scanner relative to the panel to accurately locate the laser outline template on the panel.
Other advantages and meritorious features of the method of this invention will be more fully understood from the following description of the preferred 15 embodiments of the method of this invention, the claims and the drawings, a brief description of which follows.
CA 0223~173 1998-04-17 AttorneyLk~ketNo. 60,132~45 BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a side elevation of a laser projector and panel alignment fixture assembly which also illustrates a step of the method of this invention;
Figure 2 is a top view of an aligned panel with the laser projection template 5 of the openings thereon;
Figure 3 is an enlarged view of one of the circular openings in the panel with the square laser projection template; and Figure 4 is a side elevation of a portion of a floor assembly illustrating a preferred use for the work station and method of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The illustrations of the work station and method of this invention will now be described with reference to the manufacture of a floor assembly having a 15 plurality of configured openings for plumbing and ductwork at predetermined locations from a plurality of floor panels. As set forth above, however, the laser projection work station and method of this invention may also be utilized for the manufacture of other panel assemblies having configured openings or a single panel having a circular opening for example which must be precisely located in the panel.
20 It is also possible to utilize the method of this invention for locating a plurality of configured openings in precise locations in a panel assembly, wherein the panels are preassembled, such as a floor panel assembly.
Figure 1 illustrates a laser projection work station and a step of the method of this invention wherein a panel 20 is located opposite a laser projector 22. A
CA 0223~173 1998-04-17 Attorney DocketNo. 60,132-045 laser projector may be conveniently mounted on the ceiling of the work area or on a gantry or frame. The panel 20 is first located opposite the laser projector 22.
In the illustrated embodiment, the panel 20 is located on a conveyor 24 having aplurality of rollers 26 for ease of movement of the panel. The work surface of the 5 conveyor may also include a stop mechanism 28 for accurate alignment of the panel 20 opposite the laser projector 22. In the illustrated embodiment, the conveyor 24 includes two opposed solenoid-type stop mechanisms 28 each having a retractable stop pin 30, such that the panel 20 is stopped directly beneath and aligned with the laser projector 22. The top surface of the rails of the conveyor 24 also includes 10 a plurality of spaced laser retroreflective elements or sensors 34, sometimes referred to generically as laser position indicating elements, having a top surface opposite the laser projector 22.
Upon positioning of the panel 20 opposite the laser projector 22, a laser image (36 to 40) is projected on the panel 20 by the laser projector scanner 22 15 which is a general outline of the openings to be formed in the panel 20. The laser scanner 22 is connected to a computer 42 by a cable 44 and the computer program of the computer 42 includes a data set which controls the laser projector or scanner to project a general outline of the configured openings to be formed in the panel at the precise location and orientation where such openings are desired in the panel 20 20. As will be understood by those skilled in laser projection systems and briefly described above, the laser projector or scanner 22 includes two orthogonally mounted galvanometers with a mirror mounted on each of the galvanometer shafts.
A laser is projected on the mirrors which are rotatably mounted in parallel CA 0223~173 1998-04-17 Attorney D~ketNo~ 60,132{~5 perpendicular relation in the laser projector. The rapidly sc~nning laser image is actually a laser spot which moves rapidly from location to location with sufficient speed to appear as a continuous line to the worker. Retroreflective elements or sensors 34 are normally located on the work surface or a predetermined distance 5 from the work surface to control the precise location of the projected laser outline on the panel 20. Laser projectors or scanners and computer programs for controlling the laser scanner and projecting a laser image of this type are available from Virtek Vision Corp., the assignee of the present invention.
In Figure 2, three laser images are projected on the panel 20 for illustrative 10 purposes. As described above, all three images may be projected essentially simultaneously or the images may be projected sequentially. The first illustrated laser image 36 is rectangular for cutting a rectangular opening 36A as shown in Figure 4. As described above, the rectangular opening may receive a rectangular metal duct for the heating and air conditioning system of the home or building.
15 The second and third laser projected images 38 and 40 are square and provide a template for a circular opening as further illustrated at 38A in Figure 3. As will be understood, circular openings in floor panels generally receive plumbing lines such as used for toilets, water closets, sinks, etc. A square laser generated outline 38 is preferred over a circular outline for cutting a circular opening 38A because 20 the laser projected square outline is not obstructed during the cutting operation.
That is, a circular hole cutter or drill will not obstruct the technician's view of the template during the cutting operation. Further, a laser scanner can generate a CA 0223~173 1998-04-17 Attorney D~ketNo. 60,132{~5 square or rectangular outline more quickly than a circular outline, which requires more time.
Once the general outline of the openings to be cut in the panel are projected on the panel as shown in Figures 2 and 3, the laser outlines (36 to 40) are used as 5 a template for cutting the openings. The rectangular opening 36A may be cut with a conventional circular saw, for example, following the outline provided by the laser image 36. The circular openings 38A and 40A may be cut with an annular hole cutter or drill for example using the laser generated square templates 38 and 40, respectively. As shown in Figure 1, the rollers 26 have an axis of rotation 10 parallel to the panel 20 and are located on the rails and spaced sufficiently to permit cutting of the openings (36A, 38A and 40A) on the conveyor table 24. Other information useful to the assembly person may also be generated by the laser scanner 22 on the panel 20 including, for example, the panel number, instructions, etc. Upon completion of the cutting operation, the panels may be moved to another 15 station in the assembly operation simply by retracting the stop pins 30 and moving the panel forwardly on the rollers 26.
The final step in the assembly of a floor from a plural panels by the disclosed embodiment of the method of this invention where the openings are first cut in each panel comprises assembling the floor panels on floor joists 46 as 20 illustrated in Figure 4. As described above, the floor joists 46 may be of any conventional type and may be preassembled in a frame-like structure prior to receipt of the floor panels 20, 20A, 20B, etc. The openings 36A, 38A and 40A
have now been cut in the precise location and orientation called for in the plans and - CA 0223~173 1998-04-17 Attorney D~ketNo. 60,132~45 the data set in the computer 42. The panels 20 may be attached to the studs 46 by any conventional method, including nails, adhesive bonding and the like. In a floor assembly, the panels 20 are assembled on the studs 46 in coplanar abutting relation as shown in Figure 4 and attached to the studs. In the preferred method of this 5 invention, the panels 20 are marked with the assembly location which may be provided by the laser projector 22 as described above. The floor joists 46 may be any conventional type of floor joists used in the construction industry, including conventional triangulated floor joists, metal studs or joists, or wood joists, as shown. Further, as described above, the floor panels 20 may be preassembled on 10 the joists prior to projecting and cutting the openings although in the preferred embodiment, the openings are cut in each panel in a floor as shown in Figures I
to 3 prior to assembly of the panels as shown in Figure 4. It is important to note that the openings 36A, 38A and 40A must be oriented and located between the joists 46 and thus the data set in the computer 42 should also include the location 15 of the joists where the openings are cut in panels 20 after the panels are assembled as shown.
As will be understood by those skilled in the art, various modifications may be made to the method of this invention within the purview of the appended claims.
For example, various shaped openings may be formed at predetermined locations 20 in a panel or panel assembly using the laser projection system described. In a typical floor assembly, the circular openings range from about one inch to five inches which may be easily cut with an annular hole cutter using the laser projected square template described. Larger openings may be cut with a coping saw, wherein Attorney DocketNo. 60,132~5 a circular laser projected outline may be preferred. Further, other indicia and instructions may be projected on the panels 20 by the laser scanner 22 and the panels may be marked for later assembly.
LASER PRO~ECTION WORK STATION AND METHOD OF
MANUFACTURING PANEL ASSEMBLIES HAVING CONFIGURED
OPENINGS
The present invention relates to a laser projection work station and method of manufacturing a panel assembly, such as a floor assembly for a manufactured home, using a laser im~ging system. The method of this invention may also be used to form a configured opening, such as a circular opening, through a panel at 10 a precisely predetermined location using a laser im~ging system and work station.
More specifically, the present invention relates to a laser projection work station and method of manufacturing a panel assembly, wherein the configured openings are precisely located and oriented in the panels by projecting a laser image of the openings, cutting the openings and assembling the panels to form a floor panel 15 assembly or the like.
BACKGROUND OFTHEINVENTION
Laser imaging systems have been used for some years to assemble components of an assembly, such as the components of a truss or an aircraft 20 assembly. The laser im~ging system generally includes a computer or controller, a laser scanner projector and a data set defining the pattern of the components of the assembly in the desired location and pattern. The laser scanner includes a laser which is projected on mirrors rotatably mounted in parallel perpendicular relation.
The rapidly sc~nning laser image is actually a laser spot which moves from location 25 to location with sufficient speed to appear to the assembly person as a continuous line. A plurality of images may be projected essentially simultaneously for assembly of a plurality of components, such as the planks and/or the truss I
CA 0223~173 1998-04-17 A~orney Doc~etNo. 60,132~5 connector plates on a flat surface or the components of an aircraft on a three-dimensional work surface. Such laser assembly systems are available from Virtek Vision Corp., the assignee of the present invention.
Panel assemblies of the type presently used by the manufactured building 5 industry for floor assemblies comprise a plurality of wood or fiber panels which are assembled in co-planar abutting relation on floor joists generally by nailing and/or adhesively bonding the panels on the transverse joists. Configured openings are cut through the panels between the joists to receive plumbing or ductwork at a later time, generally following assembly of the walls to the floor. The configured 10 openings include circular openings which receive pipes, drains and the like and rectangular openings to receive rectangular metal ducts for example. Modern manufactured home facilities generally assemble the floor on a wheeled support, such as used for supporting railroad cars and the assembly is then moved through an assembly line as the home is manufactured.
Manufactured homes have several advantages over "stick built" homes including reduction in cost, particularly labor cost, and precision. Further, the home is not subject to the elements during manufacture because the home is built in an indoor manufacturing facility.
The method of cutting configured openings in the floor as presently 20 manufactured requires accurately measuring the required location, size and orientation of each opening from the side edges of each panel, marking the openings on the panels and cutting the openings as marked. Where the opening is rectangular, for example, the rectangular opening must also be oriented on the Attorney DocketNo. 60,132~45 panel before cutting. Manufactured homes are made to specifications, often as ordered by a customer. Thus, several designs of manufactured homes may be made at one time in a manufacturing facility. Thus, cutting of the configured openings in the floor assembly is time consuming, requires exact measurement by relatively S skilled technicians and is subject to errors which may not be discovered until later in the manufacturing process, when others are attempting to assembly the ductwork and plumbing. In some instances, this requires cutting new openings and patching the incorrectly located openings, sometimes after the finish flooring is in place.
Another problem is cutting circular openings in the panels using markings made on 10 the panel. When a hole cutter is placed on a circular marking, the marking is at least partially obscured by the cutter, making accurate location difficult.
The laser projection work station and method of this invention utilizes a laser im~ging system which eliminates the above described problems, particularly in the manufacturer of floor assemblies, by elimin~ting the requirement for 15 measurement and marking of the location of each opening through the floor panels, resulting in improved accuracy and reduced labor cost. The laser work station and method of this invention may be used to quickly and accurately locate and orient openings through floor panels and other panel assemblies and to accurately cut circular and rectangular openings, without marking.
SUMMARY OF THE INVENTION
As set forth above, the laser projection work station and method of this invention may be utilized to manufacture a panel assembly, such as a floor CA 0223~173 1998-04-17 AUorney D~ketNo. 60,132-045 assembly, having a plurality of configured openings at precise predetermined locations using a laser imaging system. The method includes locating each or a plurality of panels requiring a configured opening therethrough opposite a laserprojector and projecting a laser image at the predetermined locations on each of the S panels comprising a laser generated general outline of the configured openings. In a typical structural panel assembly, such as manufactured home floor assembly, the openings through the panels must also be oriented and located between the transverse floor joists or support members. The method then includes cutting the openings in the panel or panels requiring an opening therethrough using the laser 10 generated outline as a template and assembling the panels in generally co-planar relation to form a floor assembly or other panel assembly with the configured openings located at the predetermined locations between the transverse support members.
Where a circular opening is required having a predetermined diameter, for 15 example, the preferred method of this invention includes projecting a laser generated square outline on the floor panel having sides equal to the diameter of the circular opening at the predetermined location of the circular opening. Then, cutting the circular opening with an annular hole cutter, for example, using the laser generated square outline as a template. Where a rectangular opening is 20 required, the method includes generating a rectangular outline of the desired opening on the panel having the required orientation, then cutting the rectangular opening, using the laser generated outline as a template. This method assures both accurate positioning and orientation of the rectangular opening.
CA 0223~173 1998-04-17 Attorney D~ketNo. 60,132~45 Where the method of this invention is used to manufacture a floor assembly, which is a preferred embodiment of the method of this invention, the panels are assembled in generally co-planar abutting relation to a plurality of transverse joists, with the openings located between the joists. The panels may be attached to the 5 joists by conventional methods, including nailing the panels to the joists and/or adhesively bonding the panels to the joists. As will be understood by those skilled in the art of manufacturing floor assemblies, the joists may be prefabricated into a rectangular frame structure with the joists extending perpendicular to the support table and panel assembly. The joist may comprise wood or metal support members 10 having an edge face which is attached to the floor panels. The method of this invention may also be utilized to cut a circular opening in a single panel, wherein the preferred method includes projecting a square outline on the panel having sides equal to the diameter of the desired circular opening, then cutting the circular opening using the laser generated square outline as a template, wherein the center lS of each side of the laser outline extends tangentially to the circular opening.
The laser projection work station of this invention is particularly adapted to cutting configured openings in panels at predetermined locations and orientations using the method of this invention. The laser work station includes a conveyor for transferring a panel beneath a laser projector having a stop locating the panel 20 beneath the laser scanner or projector. The laser projector is mounted above the conveyor and the work station includes a computer having a data set of the shape, size, location and orientation of the openings to be cut in each of the panels. The computer is operably connected to a laser scanner which controls the laser scanner CA 0223~173 1998-04-17 Attorney DocketNo. 60,132~5 to project a laser outline of the laser template on each of the panels. In the preferred embodiment of the laser projection work station of this invention, theconveyor includes a plurality of spaced rollers supporting the opposed marginal edges of the panels having an axis of rotation generally parallel to the panel and the 5 rollers are spaced sufficiently to permit cutting of the configured openings in the panels between the rollers using the laser outline template. In the disclosed embodiment, the conveyor further includes opposed generally parallel rails which guide the panels beneath the laser scanner and in the preferred embodiment, the rails include laser position indicating elements and the computer controls the laser 10 scanner to periodically scan the laser positioning indicating elements to accurately locate the laser scanner relative to the panel to accurately locate the laser outline template on the panel.
Other advantages and meritorious features of the method of this invention will be more fully understood from the following description of the preferred 15 embodiments of the method of this invention, the claims and the drawings, a brief description of which follows.
CA 0223~173 1998-04-17 AttorneyLk~ketNo. 60,132~45 BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a side elevation of a laser projector and panel alignment fixture assembly which also illustrates a step of the method of this invention;
Figure 2 is a top view of an aligned panel with the laser projection template 5 of the openings thereon;
Figure 3 is an enlarged view of one of the circular openings in the panel with the square laser projection template; and Figure 4 is a side elevation of a portion of a floor assembly illustrating a preferred use for the work station and method of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The illustrations of the work station and method of this invention will now be described with reference to the manufacture of a floor assembly having a 15 plurality of configured openings for plumbing and ductwork at predetermined locations from a plurality of floor panels. As set forth above, however, the laser projection work station and method of this invention may also be utilized for the manufacture of other panel assemblies having configured openings or a single panel having a circular opening for example which must be precisely located in the panel.
20 It is also possible to utilize the method of this invention for locating a plurality of configured openings in precise locations in a panel assembly, wherein the panels are preassembled, such as a floor panel assembly.
Figure 1 illustrates a laser projection work station and a step of the method of this invention wherein a panel 20 is located opposite a laser projector 22. A
CA 0223~173 1998-04-17 Attorney DocketNo. 60,132-045 laser projector may be conveniently mounted on the ceiling of the work area or on a gantry or frame. The panel 20 is first located opposite the laser projector 22.
In the illustrated embodiment, the panel 20 is located on a conveyor 24 having aplurality of rollers 26 for ease of movement of the panel. The work surface of the 5 conveyor may also include a stop mechanism 28 for accurate alignment of the panel 20 opposite the laser projector 22. In the illustrated embodiment, the conveyor 24 includes two opposed solenoid-type stop mechanisms 28 each having a retractable stop pin 30, such that the panel 20 is stopped directly beneath and aligned with the laser projector 22. The top surface of the rails of the conveyor 24 also includes 10 a plurality of spaced laser retroreflective elements or sensors 34, sometimes referred to generically as laser position indicating elements, having a top surface opposite the laser projector 22.
Upon positioning of the panel 20 opposite the laser projector 22, a laser image (36 to 40) is projected on the panel 20 by the laser projector scanner 22 15 which is a general outline of the openings to be formed in the panel 20. The laser scanner 22 is connected to a computer 42 by a cable 44 and the computer program of the computer 42 includes a data set which controls the laser projector or scanner to project a general outline of the configured openings to be formed in the panel at the precise location and orientation where such openings are desired in the panel 20 20. As will be understood by those skilled in laser projection systems and briefly described above, the laser projector or scanner 22 includes two orthogonally mounted galvanometers with a mirror mounted on each of the galvanometer shafts.
A laser is projected on the mirrors which are rotatably mounted in parallel CA 0223~173 1998-04-17 Attorney D~ketNo~ 60,132{~5 perpendicular relation in the laser projector. The rapidly sc~nning laser image is actually a laser spot which moves rapidly from location to location with sufficient speed to appear as a continuous line to the worker. Retroreflective elements or sensors 34 are normally located on the work surface or a predetermined distance 5 from the work surface to control the precise location of the projected laser outline on the panel 20. Laser projectors or scanners and computer programs for controlling the laser scanner and projecting a laser image of this type are available from Virtek Vision Corp., the assignee of the present invention.
In Figure 2, three laser images are projected on the panel 20 for illustrative 10 purposes. As described above, all three images may be projected essentially simultaneously or the images may be projected sequentially. The first illustrated laser image 36 is rectangular for cutting a rectangular opening 36A as shown in Figure 4. As described above, the rectangular opening may receive a rectangular metal duct for the heating and air conditioning system of the home or building.
15 The second and third laser projected images 38 and 40 are square and provide a template for a circular opening as further illustrated at 38A in Figure 3. As will be understood, circular openings in floor panels generally receive plumbing lines such as used for toilets, water closets, sinks, etc. A square laser generated outline 38 is preferred over a circular outline for cutting a circular opening 38A because 20 the laser projected square outline is not obstructed during the cutting operation.
That is, a circular hole cutter or drill will not obstruct the technician's view of the template during the cutting operation. Further, a laser scanner can generate a CA 0223~173 1998-04-17 Attorney D~ketNo. 60,132{~5 square or rectangular outline more quickly than a circular outline, which requires more time.
Once the general outline of the openings to be cut in the panel are projected on the panel as shown in Figures 2 and 3, the laser outlines (36 to 40) are used as 5 a template for cutting the openings. The rectangular opening 36A may be cut with a conventional circular saw, for example, following the outline provided by the laser image 36. The circular openings 38A and 40A may be cut with an annular hole cutter or drill for example using the laser generated square templates 38 and 40, respectively. As shown in Figure 1, the rollers 26 have an axis of rotation 10 parallel to the panel 20 and are located on the rails and spaced sufficiently to permit cutting of the openings (36A, 38A and 40A) on the conveyor table 24. Other information useful to the assembly person may also be generated by the laser scanner 22 on the panel 20 including, for example, the panel number, instructions, etc. Upon completion of the cutting operation, the panels may be moved to another 15 station in the assembly operation simply by retracting the stop pins 30 and moving the panel forwardly on the rollers 26.
The final step in the assembly of a floor from a plural panels by the disclosed embodiment of the method of this invention where the openings are first cut in each panel comprises assembling the floor panels on floor joists 46 as 20 illustrated in Figure 4. As described above, the floor joists 46 may be of any conventional type and may be preassembled in a frame-like structure prior to receipt of the floor panels 20, 20A, 20B, etc. The openings 36A, 38A and 40A
have now been cut in the precise location and orientation called for in the plans and - CA 0223~173 1998-04-17 Attorney D~ketNo. 60,132~45 the data set in the computer 42. The panels 20 may be attached to the studs 46 by any conventional method, including nails, adhesive bonding and the like. In a floor assembly, the panels 20 are assembled on the studs 46 in coplanar abutting relation as shown in Figure 4 and attached to the studs. In the preferred method of this 5 invention, the panels 20 are marked with the assembly location which may be provided by the laser projector 22 as described above. The floor joists 46 may be any conventional type of floor joists used in the construction industry, including conventional triangulated floor joists, metal studs or joists, or wood joists, as shown. Further, as described above, the floor panels 20 may be preassembled on 10 the joists prior to projecting and cutting the openings although in the preferred embodiment, the openings are cut in each panel in a floor as shown in Figures I
to 3 prior to assembly of the panels as shown in Figure 4. It is important to note that the openings 36A, 38A and 40A must be oriented and located between the joists 46 and thus the data set in the computer 42 should also include the location 15 of the joists where the openings are cut in panels 20 after the panels are assembled as shown.
As will be understood by those skilled in the art, various modifications may be made to the method of this invention within the purview of the appended claims.
For example, various shaped openings may be formed at predetermined locations 20 in a panel or panel assembly using the laser projection system described. In a typical floor assembly, the circular openings range from about one inch to five inches which may be easily cut with an annular hole cutter using the laser projected square template described. Larger openings may be cut with a coping saw, wherein Attorney DocketNo. 60,132~5 a circular laser projected outline may be preferred. Further, other indicia and instructions may be projected on the panels 20 by the laser scanner 22 and the panels may be marked for later assembly.
Claims (15)
1. A method of manufacturing a panel assembly having a plurality of panels having a plurality of configured openings at predetermined locations, comprising the following steps:
locating each of said panels requiring an opening therethrough seriatim opposite a laser scanner, said laser scanner operable connected to a computer having a data set including the configuration, size and location of said openings to be cut in said panels;
using said computer and laser scanner to project a laser image on each of said panels of a general outline of said configured openings at said predetermined locations;
cutting said openings in each of said panels requiring an opening therethrough using said laser generated general outline as a template for said openings while said panels are located opposite said laser scanner; and assembling said panels into said panel assembly with said configured openings at said predetermined locations.
locating each of said panels requiring an opening therethrough seriatim opposite a laser scanner, said laser scanner operable connected to a computer having a data set including the configuration, size and location of said openings to be cut in said panels;
using said computer and laser scanner to project a laser image on each of said panels of a general outline of said configured openings at said predetermined locations;
cutting said openings in each of said panels requiring an opening therethrough using said laser generated general outline as a template for said openings while said panels are located opposite said laser scanner; and assembling said panels into said panel assembly with said configured openings at said predetermined locations.
2. The method of manufacturing a panel assembly as defined in Claim 1, wherein said openings include a circular opening in at least one of said panels having a predetermined diameter and location, said method including projecting a laser generated square outline on said one of said panels having sides equal to said predetermined diameter of said circular opening at said predetermined location of said circular opening, then cutting said circular opening using said laser generated square outline as a template.
3. The method of manufacturing a panel assembly as defined in Claim 1, wherein said method includes conveying each of said panels requiring an opening therethrough seriatim on a conveyor beneath said laser projector, then stopping each of said panels beneath said laser projector and then using said computer and said laser scanner to project a laser image on said panel of a general outline of said openings and repeating said procedure to cut openings at predetermined locations in each of said panels.
4. The method of manufacturing a panel assembly as defined in Claim 3, wherein said conveyor includes a plurality of spaced laser position indicating elements located at predetermined positions relative to said conveyor, said method including using said computer and laser scanner to periodically scan said laser position indicating elements to accurately locate said panel relative to said laser scanner.
5. A method of manufacturing a floor assembly having a plurality of configured openings for plumbing and ductwork at predetermined locations from a plurality of floor panels using a laser imaging system, comprising the following steps:
locating each of said floor panels requiring a configured opening therethrough opposite a laser projector;
projecting a laser image at said predetermined locations on each of said floor panels requiring an opening therethrough with said laser projector, said laser image comprising a laser generated general outline of said configured openings;
cutting said openings in each of said floor panels requiring an opening therethrough using said laser generated general outline as a template; and assembling said panels in generally co-planar relation to form said floor assembly with said configured openings located at said predetermined locations.
locating each of said floor panels requiring a configured opening therethrough opposite a laser projector;
projecting a laser image at said predetermined locations on each of said floor panels requiring an opening therethrough with said laser projector, said laser image comprising a laser generated general outline of said configured openings;
cutting said openings in each of said floor panels requiring an opening therethrough using said laser generated general outline as a template; and assembling said panels in generally co-planar relation to form said floor assembly with said configured openings located at said predetermined locations.
6. The method of manufacturing a floor assembly as defined in Claim 5, wherein said openings include a circular opening in at least one of said floor panels having a predetermined diameter, said method including projecting a laser generated square outline on said one of said floor panels having sides generally equal to the diameter of said circular opening at said predetermined location of said circular opening, then cutting said circular opening using said laser generated square outline as a template.
7. The method of manufacturing a floor assembling as defined in Claim 5, wherein said openings include a generally rectangular opening in one of said panels having a predetermined length and width, said method including projecting a laser generated outline on one of said floor panels having said predetermined length and width at said predetermined location, then cutting said rectangular opening using said laser generated outline as a template.
8. The method of manufacturing a floor assembly as defined in Claim 5, wherein said panels are assembled by attaching said panels in generally co-planar abutting relation to a plurality of transverse floor joists with said openings located between said joists.
9. A method of forming a circular opening having a predetermined diameter through a panel at a precise predetermined location in said panel using a laser imaging system, said method comprising the following steps:
locating said panel opposite a laser projector, said laser scanner operably connected to a computer having a data set including the diameter and location of said circular opening;
using said computer and said laser scanner to project a laser image on said panel at said predetermined location, said laser image comprising a laser generated square outline having sides generally equal to said predetermined diameter of said circular opening; and cutting said circular opening in said panel using said laser generated square outline as a template.
locating said panel opposite a laser projector, said laser scanner operably connected to a computer having a data set including the diameter and location of said circular opening;
using said computer and said laser scanner to project a laser image on said panel at said predetermined location, said laser image comprising a laser generated square outline having sides generally equal to said predetermined diameter of said circular opening; and cutting said circular opening in said panel using said laser generated square outline as a template.
10. A method of manufacturing a structural panel assembly having configured openings at predetermined locations, said method comprising the following steps:
attaching said panels in generally coplanar abutting relation to spaced transverse support members;
locating a laser projector opposite said panel assembly, said laser projector operably connected to a computer having a data set including the configuration, size and location of said openings to be formed in said panel assembly and the location of each of said spaced transverse support members;
using said computer to control said laser projector to project a laser image outline of each of said configured openings to be formed in said panel assembly at said predetermined locations between said spaced transverse support members; and cutting said configured openings in said panel assembly between said spaced transverse support members using said laser image outline of said configured openings as a template for cutting said openings.
attaching said panels in generally coplanar abutting relation to spaced transverse support members;
locating a laser projector opposite said panel assembly, said laser projector operably connected to a computer having a data set including the configuration, size and location of said openings to be formed in said panel assembly and the location of each of said spaced transverse support members;
using said computer to control said laser projector to project a laser image outline of each of said configured openings to be formed in said panel assembly at said predetermined locations between said spaced transverse support members; and cutting said configured openings in said panel assembly between said spaced transverse support members using said laser image outline of said configured openings as a template for cutting said openings.
11. The method of manufacturing a structural panel assembly as defined in Claim 10, wherein said method includes locating a plurality of laser position indicating elements at predetermined locations relative to said panel assembly and using said computer to control said laser projector to periodically scan said laser position indicating elements to accurately locate said laser projector relative to said panel assembly.
12. A laser projection work station for cutting configured openings in panels at predetermined locations and orientations, said work station comprising a conveyor for transferring a panel beneath a laser projector having a panel stop locating said panel beneath said laser projector, said laser projector mounted above said conveyor and a computer having a data set of the shape, size, location and orientation of each of said openings to be cut in said panel operably connected to said laser projector and controlling said laser projector to project a laser outline template of said configured openings on said panel at said predetermined location.
13. The laser projection work station as defined in Claim 12, wherein said panel includes opposed marginal edges and said conveyor includes a plurality of spaced rollers supporting said opposed marginal edges of said panel, said rollers each having a an axis of rotation generally parallel to said panels and said rollers spaced sufficiently to permit cutting of said configured openings between said rollers using said laser outline template.
14. The laser projection work station defined in Claim 12, wherein said conveyor includes opposed rails having laser position indicating elements, said computer controlling said laser projector to periodically scan said laser position indicating elements to accurately locate said laser projector relative to said panels to accurately located said laser outline template on said panel.
15. The laser projection work station defined in Claim 12, wherein at least one of said configured openings to be cut in said panel is circular having a predetermined diameter and location, said computer controlling said laser projector to project a square laser image outline on said panel having sides generally equal to the diameter of said circular opening.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US4413197P | 1997-04-22 | 1997-04-22 | |
| US60/044,131 | 1997-04-22 | ||
| US1284198A | 1998-01-23 | 1998-01-23 | |
| US09/012,841 | 1998-01-23 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2235173A1 true CA2235173A1 (en) | 1998-10-22 |
Family
ID=26684073
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2235173 Abandoned CA2235173A1 (en) | 1997-04-22 | 1998-04-17 | Laser projection work station and method of manufacturing panel assemblies having configured openings |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU6282798A (en) |
| CA (1) | CA2235173A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005025199A3 (en) * | 2003-09-10 | 2005-07-07 | Virtek Laser Systems Inc | Laser projection systems and method |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105945426B (en) * | 2016-05-06 | 2018-04-13 | 上海理鑫光学科技有限公司 | Welder and welding method equipped with laser projection |
-
1998
- 1998-04-17 CA CA 2235173 patent/CA2235173A1/en not_active Abandoned
- 1998-04-21 AU AU62827/98A patent/AU6282798A/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005025199A3 (en) * | 2003-09-10 | 2005-07-07 | Virtek Laser Systems Inc | Laser projection systems and method |
| US7545517B2 (en) | 2003-09-10 | 2009-06-09 | Metris Canada Inc. | Laser projection systems and methods |
| US7826069B2 (en) | 2003-09-10 | 2010-11-02 | Metris Canada, Inc. | Laser projection systems and methods |
| US7986417B2 (en) | 2003-09-10 | 2011-07-26 | Nikon Metrology Nv | Laser projection systems and methods |
Also Published As
| Publication number | Publication date |
|---|---|
| AU6282798A (en) | 1998-10-29 |
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