EP2776644A1

EP2776644A1 - Production procedure for making building elements and building element

Info

Publication number: EP2776644A1
Application number: EP12826621.0A
Authority: EP
Inventors: Finn Borg; Steffen B. PEDERSEN
Original assignee: Borg Utviklingsselskab As
Current assignee: Borg Utviklingsselskab As
Priority date: 2011-11-11
Filing date: 2012-11-12
Publication date: 2014-09-17
Also published as: WO2013076547A1

Abstract

Production procedure for making building elements, the building elements made up of a front plate, a back plate and a structure there between and optionally insulation between front plate and back plate, wherein the procedure includes a series of process stations arranged in a production line or production cell, wherein each station is automated and receives input from a central process control computer, and wherein the building elements move through the different stations: - a first station including one or more robots, which robots initially position top and bottom frame elements and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other such that a first frame is constructed; - a second station in which a third robot places one or more plates upon the frame element layer such that the plate covers the frame element layer with the exception of areas in which disposition of doors, windows or other apertures are foreseen in the finished building component, and wherein the plate is fastened to the frame element layer; a third station in which a turning device turns the building element 180° such that the plate or plates face downwards against a base; a fourth station wherein one or more robots position a second layer of top and bottom frame elements upon the first layer and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other such that a second frame is constructed upon the first frame after which an insulation robot fills the cavities between top, bottom and remaining frame elements and the plate with insulating material; - a fifth station wherein one or more robots position and fasten a second plate layer upon the second frame element layer; - a sixth station wherein one or more robots dispose a third layer of top and bottom frame elements upon the second plate layer and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other; - an eighth station in which a third plate layer is disposed upon the uppermost frame; a ninth station wherein the finished element is moved from production line.

Description

PRODUCTION PROCEDURE FOR MAKING BUILDING ELEMENTS AND BUILDING ELEMENT

Field of the Invention

The present invention concerns a process line for making finished building elements that are substantially made of wood or processed wood, e.g. in the form of plates and the like.

Background of the Invention

In many parts of the world, construction work takes place by working, cutting and treating wood which then becomes components that by means of building workers like carpenters are formed into particularly homes, carports and the like.

Typically, by homes the case may be many uniform houses, e.g. as standard detached houses or in connection with terrace houses, low-rise apartment buildings and the like. A large number of standard elements form part thereof, elements which according to traditional production methods all are made as special elements as carpenters and joiners typically will shape the elements on the construction site.

Object of the Invention

Therefore it is the object of the present invention to automate this process such that relatively uniform building components can be rationally made on a process line by applying a number of tools. The tools are typically controlled by a central computer which is programmed such that it can convert architecture or construction drawings to input for the various machines in the process line so that the proper materials are shaped and positioned in the structure in a rational way according to the drawings read into the computer system. Description of the Invention

The invention thereby allows for a production procedure for making building elements, which building elements are made up of a front plate, a back plate and a structure there between and optionally insulation between front plate and back plate, wherein the procedure includes a series of process stations, wherein each station is automated and receives input from a central process control computer, and wherein the building elements move through the different stations:

- a first station including one or more robots, which robots initially position top and bottom frame elements and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other such that a first frame is constructed;

- a second station in which a third robot places one or more plates upon the frame element layer such that the plate covers the frame element layer with the exception of areas in which disposition of doors, windows or other apertures are foreseen in the finished building component, and wherein the plate is fastened to the frame element layer.

- A robot with an unrolling device positions a sealing strip on the outermost frame element all the way around the element and in window and door apertures and other cutouts which are not to be covered by the outer plate layer before the plates are laid on the framework. The strip has the purpose of providing a wind seal towards an adjoining element or against windows or doors or other units which are placed in the framework.

- A third station in which a turning device turns the building element 180° such that the plate/plates face downwards against the base. A robot with insulation device fills the framework down against the underlying plate after which a new plate layer is placed over this insulation.

- A fourth station wherein one or more robots position a second layer of top and bottom frame elements upon the uppermost plate layer and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other such that a second frame is constructed upon the first frame after which an insulation robot fills the cavities between top, bottom and remaining frame elements and the plate with insulating material; - a fifth station wherein one or more robots position and fasten a third plate layer or web material as vapour barrier upon the second frame element layer;

a sixth station wherein one or more robots dispose a third layer of top and bottom frame elements upon the third plate layer or web material and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other;

an eighth station in which a third plate layer is disposed upon the uppermost frame;

a ninth station wherein the finished element is moved from the production line.

Further preferred embodiments are defined in the dependent claims. The invention moreover comprises a building element made by the above mentioned production procedure where the building element includes a first outer plate to which is fastened a framework consisting of bottom and top frame elements and jointing elements that are interconnected in order to form a strong frame and where the frame elements are

Description of the Drawing

Fig. 1 shows an example of a factory layout.

Fig. 2 shows assembling robots.

Fig. 3 shows an example of a turning device.

Fig. 4 shows an example of a turning device - element raiser.

Fig. 5 shows

Fig. 6 shows a transport car

Fig. 7 shows different frame types

Fig. 8 shows

Detailed Description of an Embodiment of the Invention

The system is based on the fact that elements to be produced are recorded in a computer based drawing program and that all units in the machine line can communicate with a central computer that determines the sequence of the production of elements and determines the design of the elements based the drawings stored in the computer. For overall control of the process, a reference line is defined along the machine line such that all operations, manual as well robotic, are controlled relative to the reference line. The reference line will change side when the elements are turned such that typically the lower edge of the element will determine where the reference line is defined. Obviously, the computer can keep track of the reference line for each single element such that different elements on the machine line may have different reference lines. The machine line is therefore designed such that all processes are performed rationally in the correct sequence and that materials etc are forwarded to the various stations with proper timing.

An overview of the general layout of the factory is illustrated in Fig. 1. Plates and frame elements are convey ed/delivered in depots in the vicinity of shortening saw 10 and plate saw 1 1, respectively. The saws are here fed at the rate that components (plates and frame elements) are to be used/built in farther down the line.

In parallel with the machine line two conveyor belt are arranged for transporting the shaped components 14 to the predetermined stations.

The first frame elements are used in station 20 for making the first frame.

The first plate and strip layer are placed in the second station 30.

Alternatively, in connection with the first station there may be arranged a plate layer which before positioning of frame elements inserts a first plate upon which bottom and top frame elements and strips and "stenders" are mounted subsequently as described.

Plate and strip are secured to the frame layer by e.g. nails or clamps. These are inserted by robots provided with nail guns mounted on transverse conveyors between or above the stations so that they can reach all points on the frames made at the first station. After fastening the plate and strip layer, the frame with fastened plate and strip is moved to a turning station 40 where the element is turned around such that the plate previously situated at the top is now at the bottom. The turning device can e.g. be designed as indicated in Fig. 3.

In the shown factory layout a buffer station 50 is inserted subsequently. The buffer station serves to provide that the production rate of the various stations is adapted such that the robots will be in time to perform the work to be done without appreciably impeding the flow through the production line. Moreover, in the buffer station it is furthermore possible to perform quality control of the work performed in the first stations 20, 30. The semi-finished element, which now consists of frame plus the first plate layer, is then transferred to the next station 60. Here, the second frame layer is laid as well as insulation is filled in the recesses constituted by the plate, which is now the bottom, and the two frame layers upon each other.

In a further station 70, a second plate layer is laid such that the element now has a lower plate fastened to the first frame layer in station 20 and two frame layers made in station 30 and station 60, and a cover plate applied in the last station 70. The semifinished element then continues to an additional station 80 where a third frame layer is assembled and fastened upon the second plate layer.

In a further station 90, electric and plumbing installations are mounted in the element, i.e. upon the second plate layer limited by the third frame layer. The almost finished element is then conveyed to a further station 100 at which insulation is filled around the electric and plumbing installations provided at station 90, and finally the third and last plate layer is fastened upon the third frame layer. Hereby is thus constructed a partially finished element consisting of three frame layers and three plate layers.

At station 110 the element is raised to vertical position by turning 90°, after which the element is moved to a finishing line.

The finishing line includes a filling and drying station 120. The filling of possible joints between plate elements and the drying is effected most expediently by an infrared heat source which rapidly and efficiently dries the filling material such that when the newly filled element is conveyed to the following station 130, the element is ready for grinding. In station 130 the newly filled areas are surface-ground such that when the element is moved on to the next station 140, which is a painting booth with associated drying, the element is ready for surface treatment. The painting station is typically a paint booth with associated suction etc. Drying may again be effected by an infrared heat source but common air drying may be used as well, depending on the rate of production. After painting and drying, the element is conveyed to the following station 150 where doors and windows are fitted to the extent defined in the computer program controlling the process. After mounting doors and windows the element is conveyed to the next station 160 where an external cladding is applied. The external cladding may e.g. be a wooden covering which mounted on a list skeleton which has been mounted on the plates in connection with the production of the element at the stations 30 - 110.

In the succeeding station 170, glazing, mouldings etc. are mounted such that the element is completed and ready to be incorporated in the final building construction. From this station 170 the element is conveyed to either a buffer station 180 or to an element depot 190. The finished elements are taken out from the element depot in a given sequence to a module assembly station 200 where the elements are assembled into finished building modules, e.g. facades, roofing and the like. After assembling the elements into finished modules, the modules are transferred to a module storage 210 where the assembled and finished modules are ready to be fitted at the construction site.

Operation pos. 2, see Fig. 2

Bottom and top frame elements 21 , 22 arrive at the station 20 guided standing or flat via conveyor belt 23. Bottom and top frame elements 21, 22 can be in one or more pieces which are assembled into a length; this may be effected by glue, fish plates, sheet nails or other suitable means. This joint may occur before arrival at the position 20 or after arrival. The item is identified and gripped by 1-2 separate robot/robots 24, 25 placing them in bottom and top positions, respectively, against a stop 26 which is variable on the assembly table 27. Then the robot/robots 24, 25 pick up a "stender" 28 appearing in continuous succession for disposition between bottom and top frame elements 21, 22. The first is disposed against a stop at the end of the assembly table 27 which together with the stop in longitudinal direction form a right angle. The "stenders" 28 are then secured by clamps or other fastening means through bottom and top frame elements 21 , 22 by one or two separate robot(s) 24, 25 which is(are) equipped with clamping gun(s). This is repeated all the way across the element, and "spikerslag" and double or more "stenders" 28 are laid in where appropriate and these are fastened in the same way.

The individual items may also be entirely or partly manually disposed at the station 20 so that the robot 24, 25 fetches it from its individual position. Also, all or part of the individual operations may be manual functions.

The frames 29 are hereby constructed. Characteristics of frames are indicated below.

1. Layer - Frame Mounting

Example of frame formats: 4,800 mm x 14,000 mm.

600 mm x 1200 mm The format is variable.

Dimensions capable of being handled:

Length: fixed or variable per subcomponent

Height: fixed or variable per subcomponent

Width: fixed or variable per subcomponent

Weight: variable per subcomponent

Components/items to be assembled/machined may consist of wood, wood-based materials, composites, synthetic material, or combinations thereof.

The design of the frame 29 may vary from rectangular to mutually variable angles, see Fig. 7.

The spacing between fastening lines is variable, horizontally as well as vertically. There may be "stenders'Vcolumns, posts that abut on each other due to bearing or other purpose.

Variable angle: 0-360 degrees

Fastening for assembly of frames

Nails/clamps/screws of variable dimensions and materials.

Nails/clamps/screws which are shot/screwed or pressed in by a piston. By all assemblies an unlimited number of nails/screws or clamps can be used.

By application of other materials, welding, rivets, bolts, glue, tape or other forms of fastening materials can be used as well.

Robot unrolls and fastens a strip along all outer edges and around door and window apertures. Plates arrive as raw plates or completely cut at the station 30 in continuous sequence lying flatly and directionally guided via conveyor belts. The plates are identified and gripped on the external surface by suction lifter or other device (not shown) mounted on a robot which places them over the frame 29, beginning from the angular line at the bottom or top position. Plates are fastened with clamps by gun mounted on robot while the other robot holds the plate in correct position. When the plate has been fastened so that it is positionally fixed, the holding robot releases it and fetches the next plate while the gun robot clamps the former plate, and so on until the outer side of the frame 29 is completely covered. If raw plates are used the entire adaptation or a part thereof occurs in the process at the station.

1. Layer - Strip Mounting (see e.g. Fig. 12)

Raw material dimensions fixed or variable

Thickness as paper/film

Width example 20 - 300 mm or variable

Diameter example on roll: 200 - 300 mm or variable.

Nature of raw material: Web/roll material.

Example of spacing between the individual fastening lines from 0 to 1000 mm or variable, and in all window and door apertures or other cutouts, horizontal as well as vertical.

Fastening, examples: clamps, glue, tape.

Length of clamps variable.

Shot by air pressure via gun. 1. Layer - Plate mounting external side

Dimensions capable of being handled:

Length: Variable, most used dim. 1200 mm to 3000 mm

Width: Variable, most used dim. 600 mm to 1200 mm Thickness: Variable, most used dim. 4 mm to 24 mm

The design of the plate varies from rectangular edges to variable angles. Edge design will be rectangular on plane, key and groove, overlay or other kind of edge profile. Spacing between fastening lines: variable, most used spacing 0 mm to 1.000 mm horizontal as well as vertical.

Minimum angle: 0 degrees

Max angle: 360 degrees

The outer frame can as a minimum, however, have one right angle. The right angle can be an external corner or "stender" which is perpendicular to top or bottom frame element or a "spikerslag" emanating at right angles from a "stender" but which as a starting point will have variable angles on mutually abutting members as well.

Fastening of plates

Nails or clamps, length variable. Most used lengths 35-70 mm. Spacing between points variable. Most used spacings 0 to 500 mm.

The plates are shot into by compressed air or are pressed in by a piston, see e.g. Fig. 13.

Operation Pos. 4, see Fig. 3a - 3d

The element 1 which now consists of 1^st layer frame and 1^st layer plate is manually or automatically moved into the turning device 41. The turning device 41 then closes around the element 1 which firstly is moved to vertical position (90°), see Fig. 3 c, then around to horizontal position again (180°). If desired, the process can be continued with vertical element in the succeeding stations.

When the element is turned, the turning device opens and the element 1 is ready to continue to next position.

Turning device between 1^st and 2^nd layer

Is to turn the element 180° on the rollerway

The reference line is now moved to the right side in the conveying direction

Figs. 3a-3d illustrate the various stages in the turning operation. In Fig. 4 is illustrated an alternative element turning device. The turners in Figs. 3a-3d consist of large arches 42 arranged at each end such that the elements are controlled by means of grippers with wheels 43 and are moved around the arch during the turning operation. In the alternative turning function/carriage, the turning device can be incorporated in a transfer car, i.e. a mobile unit that may be displaced out of the machine line.

The transfer car with turning function can fetch elements for transport to other table and deliver it as well. If required for the process it is also possible to turn the element 180°. When the horizontal processes are finished, the transfer car with turning function can deliver the element in vertical position.

By picking up an element on a work table, the transfer car rolls into position opposite the table after which a set of carriers are pushed in under the element. These carriers are lifted such that the element lies thereon. They are then withdrawn to the transfer car and the element is transferred to thereto.

If the element is desired to be turned, the transfer car initiates a turning function which lifts two sets of carriers 90°, bringing the element to vertical position. The element is then laid down on the opposite side by lowering the carriers and displace then laterally.

By delivery the transfer car again drives into position opposite a work table, and the carriers are pushed out to the side at which the element is desired to be delivered. Then they are lowered such that the element is laid down on the work table in question. The carriers are now drawn back to the transfer car.

Operation Pos. 5

In this position, a buffer station 50 can be inserted optionally. The frames produced at the preceding positions can be stored temporarily here until vacancies occur at the subsequent stations.

Operation Pos. 6 (60)

The frame 1 (Fig. 3a) arrives at this position from the turning device 41, and the reference line is moved to the opposing long side. Robot/portal (not shown) with mounted insulation device starts filling insulation into the individual spaces between the "stenders" 28, see Fig. 1, down against the external plate. The amount of supplied insulation through injection tubes is measured by a sensor immediately before the material leaves the tube. The supplied amount determines the speed at which the robot moves the insulation device across the frame 1. The operation continues until each space has been filled satisfactorily based on a predefined density.

1. Layer - Insulation Example of frame formats: 4,800 mm x 14,000 mm.

600 mm x 1200 mm The format is variable.

Raw material: Wood fibres in small bags, large bags, container or other suitable delivery packing means.

Nature of raw material: Loose wood fibres or other natural fibres, compressed, moisture content 12 - 20%. The insulation may also consist of synthetic fibres of different kinds.

Installation method: Injection by blowing under pressure. Cavity sizes and shapes:

Width, variable

Length, variable

Depth, variable

Adjustable density

Most used 30 kg and 48 kg

Operation Pos. 6 (60)

Bottom and top frame elements for second frame layer - first layer was mounted in pos. 2(20), see Fig. 1 , arrive at the station while guided standing or flat via conveyor belt. Bottom and top frame elements can be in one or more pieces which are assembled to a length; this may be effected by glue, lasers, sheet nails or other suitable means. This assembling may have occurred before arrival to the position or after arrival. The item is identified and gripped by 1 - 2 separate robot(s) which position them in bottom and top position relative to the position of bottom/top frame elements and "stenders" in the underlying layer. Then the robots take "stenders" that arrive in continuous sequence for disposition between bottom and top members. Then the "stenders" are fastened by clamps or other fastening means through bottom and top frame element and down through the plate layer to the underlying frame by 1 - 2 separate robot(s) which are equipped with clamp guns. This is repeated all the way across the element and "spikerslag" and double or more "stenders" are laid where relevant, and these are fastened in the same way. The individual members may also be entirely or partly manually placed at the station so that the robot picks it up from their individual positions. Also, all or part of the individual operations may be manual functions.

Construction of the second layer is effected in an entirely corresponding way as described above for the first layer with reference to Fig. 2.

1. Layer - Frame mounting

Example of frame formats: 4,800 mm x 14,000 mm.

600 mm x 1200 mm. The format is variable.

Dimensions capable of being handled:

Length: Fixed or variable per subcomponent

Height: Fixed or variable per subcomponent

Width: Fixed or variable per subcomponent

Weight: Variable per subcomponent Components/item to be assembled/machined may either consist of wood, wood-based materials, composites, synthetic material, or combinations thereof.

The design of the frame may vary from rectangular to mutually variable angles. The spacing between fastening lines is variable, horizontally as well as vertically.

There may be "stenders'Vcolumns, posts that abut on each other due to bearing or other purpose. Variable angle: 0-360 degrees

Fastening for assembly of frames

Nails/clamps/screws of variable dimensions and materials.

Nails/clamps/screws which are shot/screwed or pressed in by a piston.

By all assemblies an unlimited number of nails/screws or clamps can be used.

Nailing is to be performed into a machined groove, see Fig. 12, down at the side of the "stender" from either side of the "stender".

Operation pos. 7 (70)

The frame 1 arrives at this position on the rollerway. Robot/portal with insulation device mounted thereon starts filing insulation in the individual spaces between the "stenders" down against the preceding insulation layer, an intermediate sheet material or web material. This station is adapted corresponding to pos. 6 (60). Alternatively, the insulation robots insulating the first beam layer can be brought into position such that the same robots can insulate the second frame layer as well. The robots may be arranged on a beam structure running above the rollerway on which the elements are conveyed in the machine line.

The amount of supplied insulation through injection tubes is measured by sensor immediately before the material leaves the tube. The amount supplied determines the speed at which the robot moves the insulation device across the frame. The operation continues until each space is filled satisfactorily based on a predefined density.

2. Layer - Insulation

Example of frame formats: 4,800 mm x 14,000 mm.

600 mm x 1200 mm The format is variable. Raw materials: Wooden fibres in small bags, large bags, container or other suitable delivery packing means.

Nature of raw materials: Loose wooden fibres or other natural fibres, compressed, moisture content 12 - 20%. The insulation may also consist of synthetic fibres of various kinds.

Installation method: Injection by blowing under pressure.

Cavity sizes and shapes:

Width, variable

Length, variable

Depth: variable

Adjustable density:

Most used 30 kg and 48 kg per cubic metre

A robot unrolls and fastens the vapour barrier along the outer edges with a few clamps.

The robot unrolls and fastens a vapour barrier along all outer edges and around door and window apertures.

Then a second layer of plates are forwarded. The plates arrive as raw plates or completely cut to the station in continuous sequence lying flatly and directionally guided via conveyor belts. The plates are identified and gripped on the external surface by suction lifter or other device mounted on a robot, disposing them over the vapour barrier, beginning from the angular line at the bottom or top position. Plates are fastened with clamps by gun mounted on separate robot while the other robot holds the plate in correct position. When the plate has been fastened so that it is positionally fixed, the holding robot releases it and fetches the next plate whereas the gun robot clamps the former plate, and so on until the frame is completely covered. If raw plates are used the entire adaptation or a part thereof occurs in the process at the station. These work routines correspond to those performed and explained with regard to Fig. 3.

2. Layer - Plate mounting internally and unrolling vapour barrier

Dimensions capable of being handled:

Length: Variable, most used dim. 1200 mm to 3000 mm

Width: Variable, most used dim. 600 mm to 1200 mm

Thickness: Variable, most used dim. 3 mm to 24 mm

The shape of the plate varies from rectangular edges to variable angles. Edge design will be at right angles to plane, key and groove, overlay or other kind of edge profile.

Spacing between fastening lines: Variable, most used spacing 0 mm to 1.000 mm, horizontally as well as vertically.

Minimum angle: 0 degrees

Max angle: 360 degrees

However, the outer frame may have one right angle as a minimum. The right angle can be an outer corner or a "stender" going perpendicularly on top or bottom frame element. Or a "spikerslag" extending perpendicularly from a "stender". But basically also having variable angles on mutually abutting members.

Vapour barrier: Web material

Fastening of plates

Nails or clamps, variable length. Most used lengths 35-70 mm

Spacing between points variable. Most used spacing 0 mm to 500 mm.

Shot in by compressed air or pressed in by a piston.

Operation Pos. 8 (80)

Bottom and top frame elements 21, 22 arrive at the station guided standing or flat via conveyor belt 12, 13. Bottom and top frame elements may be in one or more pieces which are assembled to a length, this may be effected by glue, lasers, sheet nails or other suitable means. This assembling may have occurred before arrival to the position or after arrival. The item is identified and gripped by 1 - 2 separate robot(s) which position them in bottom and top position relative to the position of bottom/top frame elements and "stenders" in underlying layer under the second plate layer. Then the robots take "stenders" that arrive in continuous sequence for disposition between bottom and top members. Then the "stenders" are fastened by clamps or other fastening means through bottom and top frame elements and down through the plate layer or web material to the underlying frame by 1 - 2 separate robot(s) which are equipped with clamp guns. This is repeated all the way across the element and "spikerslag" and double or more "stenders" are laid where relevant, and these are fastened in the same way. The individual items may also be entirely or partly manually placed at the station so that the robot picks it up from its individual position. Also, all or part of the individual operations may be manual functions.

These functions correspond to those described above with reference to Fig. 2.

3. Layer - Frame mounting - Installation layer

Example of frame formats: 4,800 mm x 14,000 mm.

600 mm x 1200 mm The format is variable.

Dimensions capable of being handled:

Length: Fixed or variable per subcomponent

Height: Fixed or variable per subcomponent

Width: Fixed or variable per subcomponent

Weight: Variable per subcomponent

Components/items to be assembled/machined may consist of wood, wood-based material, metal, composites, synthetic material, or combinations thereof.

The design of the frame may vary from perpendicular to mutually variable angles.

The spacing between fastening lines is variable horizontally as well as vertically.

There may be "stenders'Vcolumns, posts that abut entirely on each other due to bearing or other purpose.

Variable angle: 0-360 degrees

Fastening for assembly of frames

Nails/clamps/screws of variable dimension and material. Nails/clamps/screws that are shot/screwed or pressed in by piston.

By all joints an unlimited number of nails/screws or clamps can be used.

When using other materials welding, rivets, bolts, glue, tape or other kind of fastening means can be used as well.

It is to be possible to nail in a machined nail groove, see Fig. 12, down at the side of the "stender" from either side of the "stender".

Operation pos. 9 (90)

Installation layer

Complete or partial manual mounting of electrics, plumbing and ventilation. Operations can be automated as well by choice of proper equipment.

These components are laid or drawn in grooves/holes which are previously drilled, milled or sawn in "stenders", top and bottom frame elements.

Operation Pos. 10 (100)

The frame arrives at this position on the rollerway. Robot/portal with mounted insulation device starts filling insulation into the individual spaces between the "stenders" down against the intermediate plate or web material. The amount of supplied insulation through injection tubes is measured by a sensor immediately before the material leaves the tube. The supplied amount determines the speed at which the robot moves the insulation device across the frame. The operation continues until each space has been filled satisfactorily, based on a predefined density. The robot has been informed about the installation positions and dimensions thereof in beforehand.

3. Layer - Insulation

Example of frame formats: 4,800 mm x 14,000 mm.

600 mm x 1200 mm The format is variable.

Raw material: Wood fibres in small bags, large bags, container or other suitable delivery packing means. Nature of raw material: Loose wood fibres or other natural fibres, compressed, moisture content 12 - 20%. The insulation may also consist of synthetic fibres of different kinds.

Installation method: Injection by blowing under pressure.

Cavity sizes and shapes:

Width, variable

Length, variable

Depth, variable

Adjustable density

Most used 30 kg and 48 kg per cubic metre

Plates arrive as raw plates or shaped plates at the station in continuous sequence lying flatly and guided directionally via conveyor belt 13. Plates are identified and gripped at the external face by suction lifter or other device mounted on robot which place them over the vapour barrier/frame, starting from the angular line at bottom or top positions. Plates are fastened by clamps with a gun mounted on separate robot while the other robot holds the plate in the right position. When the plate has been fastened such that it is positionally fixed, the holding robot releases and picks up the next plate while the gun robot finishes clamping the previously mentioned plate, and so on until the frame has been covered completely. If raw plates are used, all or some of the adaptation in the process takes place in the station. 3. Layer - Plate mounting internally

Length: Variable, most used dim. 1200 mm to 3000 mm

Width: Variable, most used dim. 600 mm to 1200 mm

Thickness: Variable, most used dim. 3 mm to 24 mm

Minimum angle: 0 degrees Max angle: 360 degrees

Vapour barrier: Web material Fastening of plates

Nails or clamps, variable length. Most used lengths 35-70 mm

Spacing between points variable. Most used spacing 0 mm to 500 mm.

Shot in by compressed air or pressed in by a piston. Fastening of rustics/cladding

At this station it is also possible to mount rustic cladding in different dimensions. By rustic cladding is meant various forms of facade cladding.

Vertical as well as horizontal.

Fastening: Clamps or brads or other kind of fastening.

Operation pos. 11 (110)

Tilting table for raising for conveyor

Raising elements to standing position for transfer to floor conveyor. The elements may here continue to element depot 190, directly to further transport to construction site 210 or they may continue in the further process 120-180 for surface treatment and/or assembly into modules.

The tilting table 110 can also function as transfer vehicle to a new station (machining, depot or other form of handling), or it may turn about its own axis for further transporting the element in another direction vertically standing, with variable inclination or in horizontal position.

Conveyor Conveyor handles the elements by guide rail, skates, rollers, active or passive conveyor belts at the bottom (floor) or other movable unit. The position of the element is guided at the top by a guide stay fitted thereon, pin guided in a rail device suspended from the ceiling or frame system set up for the purpose. Rail can be passive or active in connection with movement of the element.

If the element is moved on to finishing treatment in pos. 12 -18, (120-180), the tilting table, pos 1 1, and the conveyor move the element to the relevant stations. Operation pos. 12 (120)

Internal filling

The element arrives at the station via conveyor belt or other transport means. Internal filling of wall and ceiling elements is performed by automatic filling tools mounted on robots. At the same station external plaster work of various kinds may e.g. be applied. The application can be effected at both sides, in case of bilateral treatment it can be done simultaneously.

Drying

Drying is performed with IR drying zones at both sides of the conveyor line.

The IR drying zones are automatically moved in longitudinal direction together with the robots.

Operation pos. 13 (130)

Internal grinding

The element arrives at the station via conveyor belt or other transport means.

Automatic grinding of filled elements is performed by robots while the element is on the conveyor line, or it may be picked up and put in its own holder.

The process is performed at one or both sides of the element simultaneously.

The element is held at the top in order to avoid that the action of the grinding brush will cause oscillations in the element.

Operation pos. 14 (140)

Internal painting The element arrives at the station via conveyor belt or other transport means. Robot spray paints while the element is on the conveyor line, or it may be picked up and put in its own holder.

The facility can be established with or without automatic colour change.

Drying

The element arrives at the station via conveyor belt or other transport means. Drying is performed with IR drying zones at one or both sides of the element .

The IR drying zones can be moved automatically in longitudinal direction together with the robots, or they may be stationary.

Operation pos. 15 (150)

Mounting of doors and windows

The element arrives at the station via conveyor belt or other transport means. Doors and windows may arrive at the station on their own transport means in the sequence in which they are to be used, or they may be taken from a fixed depot arranged at the station.

Mounting of frames for doors and windows from stationary magazines

Example of door dimensions: 600 x 2000 mm

Example of door dimensions: 2000 x 2300 mm

Example of window dimensions: 400 x 400 mm

Example of window dimensions: 4000 x 2400 mm

Windows and doors are mounted with the moving part mounted or dismounted, the fastening occurs in the rabbet or other placed intended for the purpose.

Fixed frames are supplied with fixed or loose glazing beads at sides/top/bottom so that mounting can be performed behind the glazing bead. The mounting can also be performed at the external part of the frames with mounting means/system intended for the purpose. Mounting of mouldings inside and outside can be performed manually or automated.

The same goes for the moving parts, and glazing and mouldings. Operation pos. 16 (160)

Mounting of spacer lists and cladding on external side

The element arrives at the station via conveyor belt or other transport means.

Example of frame dimension: 4.800 mm x 14.000 mm

Example of lengths 150 mm - 3.000 mm

Example of height; 12 mm - 48 mm

Example of width: 48 mm - 148 mm

The shape of the frame can vary from rectangular to mutually variable angles.

Example of distance between fastening lines: 0 mm to 600 mm (variable), vertical as well as horizontal.

Example of angle: 20 - 360 degrees

Fastening of mouldings

Nails/clamps, variable length: 50- 125mm

Nails/clamps are shot with compressed air or pressed in by piston

Screws, variable length: Example 50- 150mm

By all joints an unlimited number of nails, clamps or screws can be used.

Mounting of external cladding (160)

The element arrives at the station via conveyor belt or other transport means.

Max. frame dimension: 4.800 mm x 14.000 mm

Dimensions capable of being handled:

Example of lengths 00 mm - 5.000 mm

Example of height: 12 mm - 36 mm

Example of width: 73 mm - 198 mm Edge design can be perpendicular to plane or inclined, key and groove, overlay or other edge design.

End joint can be sharp abutment, obliquely cut, key and groove, overlay or other joint form.

Surface will be planed or sawn. Painted or untreated before mounting.

The shape of the frame can vary from rectangular to mutually variable angles.

Example of distance between fastening lines: 0 mm to 600 mm, horizontally as well as vertically (variable).

Example of angles : 0 - 160 degrees

Fastening of cladding

Nails/clamps, variable length: 50- 125mm

Nails/clamps are shot with compressed air or pressed in by piston

Screws, variable length: Example 50-150mm

By all joints an unlimited number of nails, clamps or screws can be used.

Operation Element depot (190)

The element arrives at the station via conveyor belt or other transport means. An element depot is established where frames with the finished elements are placed before they are taken out for mounting on the finished module. Elements/frames can be taken arbitrarily from the depot.

Assembly station for modules

The element arrives at the station via conveyor belt or other transport means from which they are lifted off by a portal crane or other lifting/moving device. The assembly station is provided on a large turntable 200, see Fig. 1, which can be elevated and lowered for transferring the element to transport system in floor for finished modules. Assembly of modules is effected manually or entirely or partly automated. Floor transport of modules

The finished modules are placed on roller skates running in a rail system in the floor in order to ensure best freedom of movement in the area.

The roller skates are provided without or with drive.

The rail system ensures transport from the assembly station for elements to and from the internal or external loading site/depot before further transport.

Factory layout, see Fig. 1

Process equipment

The following equipment for both automatic and manual operation - Robot tools and handling units

- Nail and clamp guns

- Frame handling tools

- Plate handling

- Insulation tool

- Filling tool

- Grinding unit

- Paint gun

- Tool for handling frames for doors and windows

- Tool for handling external cladding and spacer lists

Conveyor transport may in some cases occur in the following way: The elements are placed in adjustable frames/fixtures 210, see Fig. 6, for automatic transport in vertical position. The frames 210 ensure support of elements 1 and unhindered access to automatic working of the surfaces. The used frames 210 are reused when the elements 1 are removed at the module assembly station.

The frames 210 are driven and run on rails between the booths/work stations. Cars are made for transverse transport of the frames between the actual work stations.

Example:

1. Turning device to conveyor -> Booth line

2. Booth line -> Return line

3. Return line <-> Depot

Process control

Data acquisition

All components and elements are provided with clear markings for both electronic and visual reading. As the components goes through the processes and are assembled into finished elements 1, all accessible product and production data are logged into the system.

Examples of data that may be desired stored in the course of production:

1. Drawing number and revision.

2. Raw material supplier, batch number or similar.

3. Temperature and air humidity

4. Time and date

5. Consumed amount of nails, clamps, insulation, filling, paint etc. Quality control

In connection with data acquisition, initials and remarks from quality control staff may also be registered. Report generation

A detailed report can be generated for each element/assembled module leaving the production line and containing the desired data. CE Marking

CE marking and documentation is made according to current European standards.

Specification of consumption

Example of specifications of consumption, but the main consumers could be as follows:

• Ventilation / heating

• Compressor

• Automation equipment and robots Staffing list:

Example of staff requirements for operating the line

• Engineer/technician: 1 / shift

• Maintenance technicians: 1 / shift

• Robot-/line operators: 4 / shift

• Manual mounting of electrics, plumbing and ventilation 2 / shift

• Manual mounting of elements in transport frames 1 / shift

• Manual (dis-)mounting of doors and windows in frames 1 / shift

• Manual module assembly inch QC 2 / shift

• Interior mounting / paint finish 4 / shift

• Logistics personnel for transporting components and paint 2 / shift

• In total 18/shift

New assembling principle

The section frames (wall, ceiling, floor) are assembled on an assembly table by one or more robots or automatons that place and screw/nail the parts together into an element. The assembly table can be horizontal, inclined or completely vertical. As a rule there is to be a rectangular corner on the element/item, but it can probably be solved in other ways.

In some cases it will be necessary to use other assembly methods than nails and screws; that could e.g. fittings or glue.

Assembly table

Assembly tables, see Fig. 8, used in one or more of the positions 2, 3, 6, 7, 8, 9, 10, 12, 15, 16 and 17 are made as a solid base 81, rollers or belt upon which the robots 82, 93 can position the individual parts correctly. The table will be provided with some auxiliary units which can hold subelements, assisting the robots during the assembly process.

The robots are disposed on portals 84 across the table so that they can be moved around across the entire working area. If the table is made inclining or vertical, the robots are placed on guides along the table instead.

Function table

Assembly tables, see Fig. 9, used in one or more of positions 2, 3, 6, 7, 8, 9, 10, 12, 15, 16 and 17 are med as a solid base, rollers 91 or belt upon which the robots may position the individual parts.

The table consists of a number of reference points which are used as reference for the robots when building up an element.

The reference points can either be fixed or made with elevating/lowering function. Besides the reference points variable stops 92 are distributed on the table to be called up according to need to a wanted position. The variable stops can retain items with a programmable pressure.

Internal transport

When the elements are assembled, they are to be transported to the next work station; this may occur by crane, rollers, belts or via a transfer car.

As part of the internal transport, the elements are to be turned, see Fig. 10, in order that insulation and plate mounting can be performed from the opposite side. A turning device 41 is inserted, e.g. as illustrated in Figs. 3 or 4, for securely and carefully turning the elements without damaging the elements or twisting them out of format. The turning device can be designed as a frame turning device with an upper and lower part or as one. The turning device 41, see Figs. 3a-3d, may turn in a circular movement, part of a circular movement, with greater or lesser interruptions in the movement, example shown under. The turning station may also function as work station for other entirely or partially automated functions.

Intake of materials

The materials which the robots are to use for constructing the elements are placed within reach of the robots and positioned correctly by mechanical raisers. Materials can be conveyed to the robots via rollerways 23, see Fig. 1 , chain belts or transfer cars. Lift tables with mechanical raisers providing for supply of plates for the assembly process can be incorporated.

Insulation

The insulation head/injection device 101, see Fig. 1 1, consists of a plate lying flatly down on the framework in which there are two slots. Injection tube/hose runs in the foremost through which the material is supplied to the underlying spaces in the element. The tube can be moved in the slot from side to side and the tube can be turned 280° around so that the injection direction is variable. The tube can furthermore be elevated and lowered relative to the bottom side of the plate such that it projects more or less down into the volume space across which the device is moved. The tube mouth can be shaped according to the direction in which the supplied material is to be delivered. The tube mouth can be adjusted in relation to the size of the opening or it may be changed to a different size automatically or entirely or partially manually.

In the rearmost slot is mounted a variable "needle filter" consisting of rods that are lowered down to the bottom of the space. The ends of the rods are rounded in order not to adhere to irregularities in the bottom. Only the number of needles fitting the width of the volume space across which the device is moved are lowered. The redundant needles are held up by a catcher which can be elevated/lowered relative to the actual depth of the volume space. By asymmetric, curved or round spaces, the "needle width" is adapted during the movement. In both slots there is fitted a brush filter or other flexible sealing that seals around the injection tube and the "needle filter". A brush filter can be mounted on the needles at the sides towards the sides of adjacent needles. All filters are applied to prevent or limit material spillage.

A meter is provided on the hose for measuring the amount of material supplied under the plate. This measurement determines the speed at which the robot or other control device moves the plate across the element to be filled.

Claims

1. A production procedure for making building elements, the building elements made up of a front plate, a back plate and a structure there between, and optionally insulation between front plate and back plate, wherein the procedure includes a series of process stations arranged in a production line or production cell, wherein each station is automated and receives input from a central process control computer, and wherein the building elements are moved through the different stations:

a first station including one or more robots, which robots initially position top and bottom frame elements and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other such that a first frame is constructed;

- a second station in which a third robot places one or more plates upon the frame element layer such that the plate covers the frame element layer with the exception of areas in which disposition of doors, windows or other apertures are foreseen in the finished building component, and wherein the plate is fastened to the frame element layer;

- a third station in which a turning device turns the building element 180° such that the plate or plates face downwards against a base;

a fourth station wherein one or more robots position a second layer of top and bottom frame elements upon the first layer and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other such that a second frame is constructed upon the first frame after which an insulation robot fills the cavities between top, bottom and remaining frame elements and the plate with insulating material;

- a fifth station wherein one or more robots position and fasten a second plate layer upon the second frame element layer; a sixth station wherein one or more robots place a third layer of top and bottom frame elements upon the second plate layer and subsequently position frame elements between top and bottom frame elements, wherein the frame elements are positioned according to input from the central process control computer, and wherein the robots fasten the frame elements in relation to each other;

- an eighth station in which a third plate layer is disposed upon the uppermost frame;

a ninth station wherein the finished element is moved from production line.

2. Production procedure according to claim 1 wherein between the sixth and eighth stations there is interposed a seventh station in which is installed electric, plumbing and other installations within the wall, either by means of robots or manually, and wherein the eighth station optionally includes an insulation robot such that the cavity between the second plate layer and the second and third frames are filled with insulation material.

3. Production procedure according to claim 1 or 2, characterised in that between eighth and ninth stations is interposed a turning station (110) including a turning devices which raises the element to upright position and transfers the element to a finishing line, the finishing line including one or more of the following stations:

- a station (120) including one or more robots arranged at either side of the element for filling and subsequent drying of the element;

- a station (130) including one or more robots arranged at either side of the element for (plane) grinding and cleaning of the surfaces of the element;

- a station (140) including a booth wherein one or more robots arranged at either side of the element for painting and drying;

- a station (150) including one or more robots arranged at either side of the element for mounting doors and windows;

- a station (160) including one or more robots arranged at either side of the element for mounting external cladding including a strip or list layer for mounting the covering;

- a station (170) including one or more robots arranged at either side of the element for mounting glazing and mouldings;

- a transport car for transferring elements to an element depot (190).

4. Production procedure according to one or more preceding claims, characterised in that between individual stations buffer stations (50, 180) are interposed, in which buffer stations temporary storage of frames, subelements or elements may be effected.

5. Production procedure according to one or more preceding claims, characterised in that at the end of the production procedure there is provided a module assembly station (200) including a rotary platform, a number of assembling robots, a crane robot for taking wanted elements from the element depot (190) and bringing them to the assembly station where the robots assemble the elements into finished modules in the form of roofs, facades, walls, and wherein the module assembling station furthermore includes a second crane robot for moving the finished modules to an end product storage (210).

6. Production procedure according to one or more preceding claims, characterised in that a shortening saw and a plate saw are arranged before the first station (20), the saws together shaping all the frame elements and plates used in the subsequent stations, and that a conveyor belt is arranged concurrently with the other stations for transporting the shaped frame elements and plates to the predetermined stations for incorporating the shaped frame elements and plates.

7. Production procedure according to claim 1 wherein before the first station there is provided a plate magazine from which a plate is placed in the first station before the robots position the bottom and top frame elements, and wherein the third station is bypassed.

8. Production procedure according to claim 1 wherein before or after or instead of the third station and/or fourth station there is provided a buffer station, in which buffer station one or more transfer cars can move building elements out of the production line or into the production line, where outside the production line there may be provided a buffer space for building elements or one or more manual stations for manual mounting of building installations.

9. A building element made according to a production procedure according to any of claims 1 to 8, characterised in that from an outer side the element includes the following subelements in the said structure:

- an outer plate layer suited either for an outer or for an inner wall or which outer plate is made ready for further processing, and wherein the plate layer covers the front or back side of the building element with cutouts for windows and doors according to need;

- a first frame made up of top and bottom frame elements and further reinforcing frame elements between bottom and top frame elements, wherein the frame is fastened to the back side of the outer plate layer;

- a first central plate layer fastened to the first frame;

- a second frame made up of top and bottom frame elements and further reinforcing frame elements between bottom and top frame elements, wherein the frame is fastened to the first central plate layer;

- a second plate or film central layer fastened to the second frame;

- a third frame made up of top and bottom frame elements and further reinforcing frame elements between bottom and top frame elements, wherein the frame is fastened to the second central plate/film layer and/or the second frame;

- a second plate outer layer suited either for an outer or for an inner wall or which outer plate is made ready for further processing, and wherein the plate layer covers the front or back side of the building element with cutouts for windows and doors according to need;

10. Building element according to claim 9, characterised in that insulation is provided between the various plate layers, preferably a wood fibre insulation.

1 1. Building element according to claim 9, characterised in that the wanted electric, plumbing and/or draining installations are inserted in the joisting before positioning the second plate outer layer.