IE80460B1 - Method of and apparatus for manufacturing timber frame house construction kits - Google Patents

Description

METHOD OF AND APPARATUS FOR MANUFACTURING TIMBER FRAME HOUSE CONSTRUCTION KITS The present invention relates to a method and apparatus 5 for manufacturing timber frame house construction kits.

Timber frame house construction has been used for many years as an efficient method of constructing houses where the main structural framework is constructed from timber.

An outer leaf of block or brick work provides the exterior surface to the house, although in some climates the outer leaf is also of timber construction. Generally, in house construction in Ireland, an external leaf of brick work or block work is used so as to provide a long-term weather proofing and decorative function.

Currently, timber frame construction kits are manufactured in a plant and transported to be assembled on site where the house is to be constructed. Heretofore, construction of these kits has been by skilled or semi-skilled operators where the external wall panels and internal wall panels, roofs and floor sections are manufactured by skilled craftsmen and as such, the methods of manufacture used have not leaded themselves to semi-automated or automated manufacture, except where highly complex machinery is used. The cost of such machinery is prohibitive and is only justifiable on a very large economic scale.

The object of the present invention is to provide an improved method of manufacturing the components of a timber frame construction kit, which method lends itself to the use of semi-automated or automated procedures not requiring extremely elaborate, sophisticated and expensive equipment, but which can also be implemented using manual procedures at a lower cost than heretofore.

The present invention provides a method of manufacturing a timber frame house construction kit comprising the steps of: manufacturing internal wall panels in a first stream of manufacture; manufacturing external wall panels in a second stream of manufacture; manufacturing floor panels in a third stream of manufacture; manufacturing roof assembly trusses in a fourth stream of manufacture; manufacturing spandrels in a fifth stream of manufacture; manufacturing the ladder assembly components in a sixth stream of manufacture; marshalling components manufactured off site, together with required building materials; and transferring the completed elements manufactured in the six streams and the other components and materials to a central storage collection area and loading the items in a co-ordinated manner onto a trailer or the like for transportation purposes.

Advantageously, the method of manufacturing comprises as a separate step in each of the first to the sixth streams of manufacture, marking the relationship of the components of each element to one another, identifying the components and their relative position and location as part of the * kit, transferring the marked components onto a separate manufacturing section stage, performing the manufacturing * operations, conducting relevant checking procedures which ensure manufacturing compliance with requirements prior to the transfer to the central storage area.

Preferably, the manufacture of the internal wall panels comprises the steps of cutting head and sill plates and studs to the required lengths; transferring the marked head and sill plates to an assembly line; laying the studs and other horizontal and vertical components on the locations as indicated on the marked heads and sills; installing one or more lifting eyes on the heads; assembling the structure using nailing devices; securing wall panelling to the completed structure with the exception of door openings and window openings by nails and transferring to the central storage area.

Optionally, the manufacture of the internal wall panels may comprise marking the position of the studs and all other horizontal and vertical elements on the head and sill plates.

Conveniently, the manufacture of the external wall panels comprises the steps of cutting head and sill plates and studs to the required lengths; marking the position of the studs and all other horizontal and vertical elements on the head and sill plates; transferring the marked head and sill plates to an assembly line; laying the studs and other horizontal and vertical components on the locations as indicated on the marked heads and sills; installing one or more lifting eyes on the heads; assembling the structure using nailing devices; securing wall panelling to the completed structure by nails with the exception of door openings and window openings where required, attaching breather paper on the outside wall surfaces by means of rows of staples aligned with studs position; and where required attaching damp proof courses to ground engaging surfaces, and transferring to the central storage area.

Additionally, the floor panels are manufactured using the 10 steps of cutting the elongate components to the required lengths; marking the location of each joist on the header joist; marking the location of each trimmed joist in relation to the header joist and the parallel trimmer; marking the position of solid blocks on appropriate joists; assembling a floor by laying the header joists on a horizontal surface and laying the joist in correct alignment as indicated on the marked header joist and trimmer, and laying the blocks in relation to the joists; nailing the elements together to form the overall structure; attaching floor sheeting to upper surface of the floor panel, with the exception of openings formed in the floor structure.

Advantageously, the manufacture of the roof assembly trusses comprises the steps of cutting the components to the required length, placing the components on a truss assembly bench, adjusting the bench to suit the particular truss, assembling the truss components using truss plates, placing the trusses into batches and strapping the batches together.

Preferably, the manufacture of spandrels comprises the steps of cutting the spandrel components to the required dimensions and the approximate angles, marking a soleplate to indicate the location and spacing of components, assembling the components by nailing, if required covering one side of the spandrel with plywood, and also if ► required applying breather paper to an external surface.

«V Conveniently, the manufacture of the ladder assemblies comprises cutting the ladder components to the required dimensions to correspond with roof assembly trusses of the house, and assembling the ladder components by nailing.

Additionally, the method of manufacture includes manufacturing soffits in the sixth stream of manufacture, including cutting the components to the required size, applying vents to the soffits, staining the soffits and strapping with the assembled ladders for the particular house.

The present invention also provides an apparatus for manufacture of a wall frame, comprising a longitudinal beam for supporting a foot rail and a longitudinal beam for supporting a head rail, respectively, of the wall frame, and a transverse beam which is located between the two longitudinal beams and, substantially perpendicular to each longitudinal beam, the transverse beam being telescopic so that the head and foot beams are moveable relative to each other, further wherein the transverse beam includes at a position along its length an intermediate stud clamping means for clamping the stud along its length while it is being operated on by the apparatus, the stud clamp applying pressure on the stud forcing the stud to abut a stud locator plate positioned below the stud and wherein the transverse beam also carries an auxiliary control station to allow the operator to control the manufacture process and further wherein the transverse beam also carries a door head guide. „ Conveniently, an apparatus for cutting a groove in the or each stud is also provided at a position along the length of the transverse beam, whereby in use the apparatus cuts a groove in the or each stud, having dimensions corresponding to a centre bridging rail so that the groove on the or each stud can accommodate the centre bridging rail therein; optionally, wherein means are provided to change the relative position of any one of the tools provided along the length of the transverse beam; and optionally, wherein each longitudinal beam is provided with at least one of the devices selected from the following: rail locating device for locating the head rail and foot rail correctly so that the respective leading edges are aligned with the leading face of the first stud; rail clamping device for engaging with a pivoting end clamp device of a stud frame index means.

Preferably, the rail locating device comprises a rail locator hydraulic ram moveable between an operation position in which the ram abuts with the rail and an inoperational position in which the ram is retracted away from the rail; and optionally, further including clamping means for clamping the rails at an input side of the apparatus, the clamping means including clamping rams, a fixed clamp plate and a moveable clamp plate, whereby in use, the rail is located between the fixed clamp plate and the moveable clamp plate and when the clamping rams are activated the moveable clamp plate is urged against the rail so that the area is sandwiched between the moveable clamp plate and the fixed clamp plate.

Advantageously, the apparatus further comprises an input conveyor means for carrying a wall panel frame towards the apparatus and an output conveyor means for carrying a wall panel away from the apparatus; and optionally, wherein the transverse beam supports at each end thereof a nailing tool for nailing a stud to the foot rail and to the head rail, respectively.

The invention will hereinafter be more particularly described with reference to the accompanying drawings, which illustrate an embodiment of the method according to the invention.

In the drawings: Figure 1 is an exploded perspective view showing the elements of a typical timber frame house; Figure 2 is a flowchart illustrating the steps in the manufacturing method according to the invention; Figure 3 is a layout of a factory floor implementing the method of the invention; Figure 4 is a side view of a wall panel with noggin side centre bridging; Figure 5 is a side view of a wall panel with rail centre bridging; Figure 6 is a plan view of apparatus for assembling the wall panels shown in Figures 4 and 5; Figures 7(a) and (b) are detailed views on a larger scale of a rail locator in the apparatus of Figures 6 in an engaged position and a disengaged position, respectively; Figure 8 is a further detailed view of a rail clamp of the apparatus; Figure 9 is a further detailed view of a door head guide of the apparatus; Figure 10(a) and (b) are further detailed views of pivoting end stud clamps; Figure 11 is a further detailed view of a middle clamp for studs; Figure 12 is a further detailed view of an apparatus for cutting a groove in each stud; Figures 13(a) and (b) are further detailed views of a tool for firing nails into the stud in a lower position and in an upper position, respectively; and Figure 14 is a further detailed view of a frame index mechanism of the apparatus.

Referring to the drawings, and initially to Figure 1, a typical timber frame house comprises a ground floor 10, a ground floor wall structure 20, a platform floor 30, first floor wall structure 40 and a roof structure 50. The ground floor structure 20 shown has four external walls 21 and one internal wall 22. Each of the walls 21, 22 has a head plate 24 and a sill plate 25 which is at the bottom of the wall structure. The walls are provided with door openings 26 and window openings 27 as required. Each window opening is provided with a lintel 28. The vertical members of the wall structure comprise vertical studs 61 extending between the head and sill plates 24, 25. The studs 63 at either side of the window openings 27 are usually either double studs or cripple studs which are reinforced to take the additional load at that particular point. The first floor structure 40 is of similar construction to the ground floor structure 20 and can of course be provided with a number of internal walls as required, even though these are not shown on the drawings. All of the wall structures are provided with plywood sheeting at one side thereof to form the wall structure.

The platform floor 30 comprises a number of parallel joists 31 and two header joists 32 and 33. A trimmer 34 is used to define the opening for a stairwell. Extending transversely across the joist are solid blocks 37 which are located to support the partition in the structure of the floor. The entire floor surface is then finished off with the floor sheeting 38. Construction of the floor 10 is similar to the floor 30, except that it is a ground floor level. (The ground floor in a house is usually of concrete construction.) The roof structure 50 generally comprises a plurality of roof trusses 51 connected together by braces 52.

When designing a new house to be constructed from timber frame construction methods, complete drawings of the roof structure, ground floor structure and any upper floor structures are prepared in detail, listing the dimensions of each element and of the relative location of each element to the co-operating elements of the structure.

In accordance with the invention, these detailed drawings and manufacturing instructions are received by the manufacturing plant which then separates the drawings and manufacturing instructions and distributes them to seven specific areas. As shown in Figure 2, the detailed drawings and manufacturing instructions are passed to each section dealing with the construction of the following items:(a) internal walls panels 101; (b) external wall panels 111; (c) floor panels 121; (d) truss section 131; (e) spandrel section 141; (f) ladder assembly section 151; and (g) central collection and co-ordination sections 127, 200.

The method of manufacturing in each section will now be considered in detail, after which the combination of the individual items made by the sub-methods will be discussed and the manner in which they are co-ordinated so as to achieve an efficiently manufactured kit at a low manufacturing cost.

The method of manufacture will now be discussed in relation to the flowchart shown in Figure 2. As indicated in box 101, the internal wall manufacturing section receives the drawings and manufacturing instructions for all the internal walls components. At step 102, all elongate timber construction elements are cut to their required lengths. Elongate joins are also made at this point. The head and sill horizontal elements may be marked to indicate the location of the vertical studs and to identify particular internal wall panels. The location of any double stud and any cripple stud is also marked on the appropriate position on the head and sill plates as are the location of any lintels on the head plate. During the marking procedure, the studs are marked according to the production specification for the particular job as are also the positions of the door and window openings on the heads and sill plates. Each particular panel is marked so that they can be identified in relation to the name of the client, the positioning of the wall panel in the proposed building, the number of the wall panel and the length of the wall. This information is transferred onto the headpiece so that it can be readily identified at a later stage during production and construction of the house.

Each head and sill are marked with an arrow indicating which side of the panel has to be covered with plywood sheeting. The head and sill are also marked for extension plywood or extension breather paper if required for a particular panel.

The marked heads and sills are transferred to the assembly section 102. The same procedure for marking the external walls is followed in accordance with step 111, as is followed in step 101. When the heads and sills of the external wall panels have been marked, they are transferred to the external panel assembly section 112.

At section 102, the head and sill plates are placed on the assembly line so that the panel is constructed in a horizontal orientation. The head and sill plates are placed longitudinally on the assembly line, parallel to one another. The various stud components and lintel components are then nailed to the head and sill plates in the marked locations by pneumatic nailing appliances.

A wall panel 401 with noggin centre bridging 408 is shown in Figure 4 and the wall panel 400 will now be described with particular reference to Figure 4.

The wall panels 400 are fabricated from a foot rail 401 and a head rail 402, with a first stud 403 and final stud 404 forming a perimeter frame. Further intermediate studs 405 are spaced at common centres, with features such as the door opening 410 formed by positioning cripple studs 406 adjacent to, and between intermediate studs 405 spaced at a larger centre, whereby these cripple studs 406 support the door head 407. To allow for the joining of an adjacent wall panel 400 on erection of the house, it is common practice to have two studs 405' positioned at close centres. To improve the stability and rigidity, the wall panels 400 may be centre bridged, i.e. noggins 408 are positioned alternately at either side of the central transverse longitudinal axis of the wall panel 400.

An alternative means of centre bridging is shown in Figure 5 with wall panel 500. In the wall panel 500, each stud 503,504,505 has a groove cut therein to accept a rail 511 positioned down along the centre of the wall panel 500 parallel to the foot and head rails 501,502, respectively. This provides an improvement over the structure of the wall panel 400, and furthermore provides a more economic method of production.

Referring now to Figure 6, an apparatus for assembling both of the above types of panel 400,500 is shown. The apparatus is indicated generally by reference 600 and is adjustable to accommodate the dimensions of the timber commonly used both in the panels for internal and external walls of a timber framed house. The apparatus 600 comprises a transverse beam 601, supporting at each end thereof a nailing tool 612,613 for nailing the foot rail 401,501 of the wall panel 400,500 respectively. The transverse beam 601 also includes at intermediate positions along its length, a middle stud clamp 671, an apparatus 611 for cutting a groove in the studs to accommodate the centre bridge 511 of the wall panel 500, auxiliary control station 620, and a door head guide 607. The relative position of each of the aforementioned intermediately located devices can be independently adjusted along the transverse beam 601 as required to suit the height of the frame being manufactured. The stud clamps 655 are designed to put pressure on the top face of the studs (403,404,405,503,504,505) positioning the stud up to the stud locator plates 653 beneath the stud and at the front face of the stud, thus leaving the leading face of the stud available and acceptable for the insertion of a further stud at close centres.

At one end of the transverse beam 601, there is a longitudinal foot rail beam 624 and at the other end of the transverse beam is a longitudinal head rail beam 625. The transverse beam 601 is telescopic thereby allowing the head rail beam 625 to be moved closer to or further away from the foot rail beam 624 so as to accommodate differently dimensioned wall panels during manufacture. Input roller tracks 630 and output roller tracks 631 are also provided to support the head and foot rails at the input side of the apparatus 600 and to support the assembled frame at the output side of the apparatus 600. The centres of the transverse beam 601 and the input and output roller tracks 630,631, respectively are adjustable to suit the height of the wall panel being manufactured, the foot assembly remaining stationary, while the head assembly is adjusted telescopically into the support frame, leaving the sides of the conveyor readily accessible. This improves the ergonomics of the apparatus 600 by allowing the operators easy and comfortable access to the wall panel so they can carry out any subsequent operation required. Each longitudinal beam 624,625 is provided with the following devices: rail locating device 604, 605, foot and head rail clamps respectively 660, pivoting end clamp for stud 655, frame index mechanism 710, and respective foot and head push button control stations 715,716. These can be adjusted by an amount corresponding with the adjustment of the transverse beam 601 as required, so as to suit the height of the wall frame being manufactured. The components of the apparatus can be controlled from the main control panel 640.

Referring to Figures 7a and 7b, the operation of the foot and head rail locating device 604,605 respectively will be described. When the operator loads the foot rail 401,501 and head rail 402, 502 on the apparatus 600, it is essential to provide an initial location to align the leading edges of the foot and head rails respectively, with the leading face of the first stud 403, 503. The operator depresses the push button located on the main control panel 640 and selects the head rail and foot rail locator rams 642, respectively, to simultaneously be engaged so that the respective rails are in contact with their respective locator rams 642 as shown in Figure 7a. Having fulfilled the function of marking the initial location, the rail locator ram 642 then acts as a top clamp for the head rail and foot rail respectively. It is essential to have this top clamp in place when locating and nailing the final stud 404,504 since the head and foot rails are not at the stage, held by the clamps provided at the input side of the apparatus 600. Since the rail locator rams are included on the rail locating device mounted on an adjustable slide 645 on the transverse beam 601, the lateral and vertical positions of the rail locator rams 642 can be quickly adjustable to suit the thickness and height of the timber being used to manufacture the wall panels. The adjustable slide 645 can move in both the directions indicated by arrows C and D on Figure 7(a).

We refer now to Figure 8 which shows the foot and head rail clamps 660. Having appropriately located the head rail 502 and foot rail 501, the head and foot rails are then clamped at the input side of the apparatus 600. To clamp the rails, the operator depresses the push buttons located adjacent to the clamps. As shown in Figure 8, the clamping rams 652 are activated and force the moveable clamp plate 651 to engage the rail 502 so that the rail 502 is sandwiched between the fixed clamp plate 650 and the moveable clamp plate 651. The fixed plate locator 653 for the stud and the end clamp 655 for the stud are engaged with the stud. After nailing the rails to the stud along the nailing line indicated by numeral 700 and having cut a groove in the stud, the clamps are retracted to allow the fabricated assembly to be indexed forward under the action of the frame index pushing device 660.

Referring now to Figure 9, a door head guide which is mounted on the transverse beam 601, is adjusted to the required position. The door head guide allows the operator to locate a door head 407, 507 against the side fence, manually nailing as required. The door head guide can be moved laterally as shown by the directions of arrows E.

As described above with reference to Figure 4, wall panel 400 includes two transverse studs 405' which are positioned at close centres. The apparatus of the present invention allows the transverse studs 405' to be positioned at very close centres as will be described below.

Referring now to Figures 10(a) and (b), the means for clamping the stud according to the present invention will be described. The stud 403 is clamped at each end thereof by means of clamps 655. These clamps 655 pivot about pivot point 659 to allow easy access for the operator to insert the stud 403 into the correct position located by the stud locator plate 653. The operator depresses a push button conveniently located centrally in the auxiliary control station in order to activate the end clamps 655 for the stud. The clamping force is arranged at an angle so as to hold the stud 403 at each end against the stud locator plate 653, so that any twist in the timber can be adjusted by the operator prior to initiating the nailing operation. The position of the clamp 655 can be adjusted as appropriate by movement of an adjuster slide in the direction of arrows F and/or G. After the nailing of the head and foot rails to the stud, and having cut a groove in the stud, the clamps 655 are automatically released, thereby enabling the operator easy access for the loading of the subsequent stud.

With the device shown on drawings Figures 10a and 10b, the fixed stud locator plates 653 are provided at each end of the stud 405' at the operator side, with pivoting overhead clamps 655 again provided at each end of the stud.

Figure 10a illustrates a stud being loaded from overhead by the operator, such that the pivoting clamping ram 656 is pushed into a vertical position to allow the insertion within the frame of the lateral stud member locating up to the stud locator plates 653, the clamping ram 656 then springing back over the top surface of the stud.

Upon initiation by the operator, the clamping rams 656 at each end extend at an inclined angle to the stud, thereby pushing the stud up to the stud locator plate 653.

After nailing through the head and foot rails it is necessary for the frame to be advanced forwards away from the operator, by a distance equal to the reguired centre of the next stud to be inserted into the frame. To allow this to occur, the top clamping rams 656 are retracted thereby allowing a free passage for the frame to be advanced away from the stud locator plates 653. This has the advantage that a second stud can be inserted immediately adjacent to the previous stud, after advancing the frame by one stud thickness, since the present invention has the advantage that there is no minimum stud centre distance imposed by the design of the apparatus of the present invention.

Referring now to Figure 11, when a machine head cutting device is to be used to cut a groove in the stud so as to accommodate a centre bridging rail, a middle clamp 671 for the stud is used so as to prevent the stud deflecting in the centre. Without the middle clamp 671, the stud would deflect in the centre due to the cutting pressure exerted by the cutting apparatus. Use of the middle clamp reduces the tendency for the timber to split out as the cutting device breaks through the face of the timber. The operation of the middle clamp 671 is linked with the operation of the end clamps 655 at the ends of the stud.

The middle clamp 671 is pivotable between position A (shown in Figure 11) in which the clamp is disengaged from the stud and position B in which the middle clamp is engaged with the stud 403 holding it in position. The middle clamp 671 is operated under the action of a clamping ram 672 and is arranged to automatically pivot into the disengaged position [position A] after the rails have been nailed to the stud and a groove has been cut in the stud, thus allowing the operator easy access for loading the subsequent stud. The relative position of the middle clamp 671 along the transverse beam 601 can be adjusted using the vertical slide adjustment 673 and horizontal slide adjustment 674.

Referring to Figure 12, the device for cutting a groove in the stud is shown. The operator operates a switch conveniently located on the central auxiliary control station 640 and selects the cutting device for cutting a groove in the stud to operate within the operation cycle of the apparatus 600. After the operator has inserted the stud and after nailing the stud to the rails, a machining head high speed motor with cutting device 680 cuts a groove in the centre of the stud which is then capable of accommodating a centre bridging rail which will be inserted in the groove at a later stage. Lateral and vertical adjustments can be made using vertical slide adjustment 681 and horizontal slide adjustment 682 so as to accommodate positioning of the rail centre as the panel height is adjusted, and to suit the dimensions of the timber being used.

Referring now to Figures 13(a) and (b) nail tools.612,613 provided at the foot and head rails of the apparatus 600 are selected by the operator using switches conveniently located on the central auxiliary control station 620. The nail tools 612,613 are programmed during the machine cycle to provide two nails through both the foot and head rails. The nails are splayed to provide improved holding power particularly in the end grained timber of the stud.

Referring now to Figure 14, an automatic indexing means for urging the wall panel forward in the direction of arrow H towards the output side of the apparatus is indicated generally by reference numeral 710. The indexing means 710 comprises a frame index ram 713. The operation of the frame index ram 713 selected from the operator keypad on the main control panel 640, and is incorporated into the operation cycle of the apparatus 600. The required common index dimension is set by the operator on the index setting scales 711 provided. After nailing of the rails to the stud and cutting a groove in the stud, the frame is indexed forward to the pre-set dimension, the frame is prevented from over running of the pre-set dimension by resistance provided to the studs by the friction anti-overrun device 712. There is also an adjustable stop block 714 to stop the frame index ram 713 from extending too far. For non common index dimensions, a manual mode of operation can be selected from the operator interface on the main control panel upon which, after nailing of the rails to the stud and cutting a groove in the stud, all clamps are released leaving the operator free to manually index the frame to the required dimension before inserting a further stud.

Removable lifting eyes are inserted approximately 1/5 of the panel length from each end through a hole in the head plates. These eyes are usually of rope which can be removed during the construction of the house. The wall panel sheeting is then nailed to the studs at the spacing intervals as required by the particular job. A damp proof course is then applied to the soleplate, if the internal wall panel is being used as a ground floor wall positioned over a non-timber ground floor. After manufacture, assembly and checking, the completed internal wall panels are transferred to the central location area 200 (See Figure 2c).

Construction of the external walls panels is carried out a step 112. The procedure for the manufacture of the external walls panels is the same as for the internal walls, as discussed in relation to section 102, except that the breather paper is tacked in position on all external facing walls with a breather paper lap provided as required at the bottom or side of each panel. Breather paper is then applied over the plywood panel and is stapled in position, the staples being lined in accordance with the positions of the studs so as to give an indication of the location of each stud. When the external wall panels are completed and checked, they are then moved to the central collection point 200.

As shown in section 121, the floor panel manufacturing section receives the drawings and manufacturing instructions for all the floor panels. At 122, the list of components is identified and transferred from the storage depot. At 123, the components are cut and any lengths are joined by a truss bench. At 125, the floor panels are assembled by laying out the joists in parallel relationship to one another in accordance with the spacing and marking indicated on the header joist at each end of the floor. The joists are secured to the header joist by nailing. Solid blocks are inserted between the joists where indicated, also by nailing. Trimmed joists, trimmers and trimming joists are assembled in accordance with instructions. Floor sheeting is then laid over the structure and nailed in position in accordance with the specified instructions over each joists. Lifting eyes are installed in the floor panel. The finished floor panels are then finally checked and transferred to the central storage area from 126 to 200.

Manufacture of the roof truss assembly will now be discussed. At step 131, the roof truss assembly section receives the drawings and manufacturing instructions for the components for the roof. The stock required for each assembly is obtained from the central depot as shown at 132 and is cut to the required length at 133. Each truss is manufactured by being set up on a truss assembly bench which is adjusted to suit the size required. The elements of the truss are assembled together using truss plates. Each finished truss is assembled and placed on a trolley. When a batch of trusses has been manufactured, the batch is strapped together and all identification marks are placed on the trusses. The batch of assembled trusses is then brought to the central collection area 200.

The spandrel manufacturing section receives the drawings and manufacturing instructions for the spandrels at 141. The spandrel panel may be for internal or external wall panels or, generally triangular in shape, when forming a gable wall. Wall components are cut to the required dimensions and at the appropriate angles 142. During the assembly process at 143, the soleplate of the spandrel is marked out and then the spandrel is assembled. The spandrel is covered with plywood if required and also with breather paper if in relation to an external wall. After the spandrel is checked for accuracy, it is then transferred at 144 to the central collection area 200.

The ladder assembly section receives the detailed drawings and manufacturing instructions for all roof ladders and soffit ventings required in a particular house at 151.

The ladder components are cut in accordance with the instructions to correspond with the truss instructions of the corresponding house 151. The ladder rafters are transferred from the truss assembly line 131-135 and the ladder is assembled to the ladder rafters in accordance with the instructions for the particular house, assembled and checked and transferred at 153 to the central collection area 200. The required soffits are also manufactured in this section and are cut to the required size, vented and stained and strapped together with the assembled ladders.

The required drawings, component lists, co-ordinate instructions and loading instructions are transferred from section 100 to 127. The items not manufactured in the plant and required building materials are assembled at 128 and transferred to the central collection area 200.

At the central collection area 200, all the components for each individual kit are assembled together at one point and are prepared for loading on a truck. The components are all loaded in a safe manner and are loaded in accordance with the specific loading instructions on the basis that the first materials required on the site are last to be loaded on the truck. Therefore, generally the first components which are loaded are the wall panels, both external and internal, for use in construction of the first floor, followed by the floor panels, followed by the ground floor wall units, followed by the roof trusses and followed by any other components such as felting, stairs, and building materials. The kit is then ready for transportation to the site of construction of the house.

Figure 3 illustrates how the different manufacturing streams and method steps are implemented on a factory floor layout. The numerals used correspond to the numerals used to label the steps as outlined in Figure 2.

It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible without departing from the scope of the invention as defined in the appended claims .

Claims (20)

CLAIMS :

1. A method of manufacturing a timber frame house construction kit comprising the steps of: manufacturing internal wall panels in a first stream of manufacture; manufacturing external wall panels in a second stream of manufacture; manufacturing floor panels in a third stream of manufacture; manufacturing roof assembly trusses in a fourth stream of manufacture; manufacturing spandrels in a fifth stream of manufacture; manufacturing the ladder assembly components in a sixth stream of manufacture; marshalling components manufactured off site, together with required building materials; and transferring the completed elements manufactured in the six streams and the other components and materials to a central storage collection area and loading the items in a co-ordinated manner onto a trailer or the like for transportation purposes.

2. A method of manufacturing a timber frame house construction kit as claimed in Claim 1, comprising as a separate step in each of the first to the sixth streams of manufacture, marking the relationship of the components of each element to one another, identifying the components and their relative position and location as part of the kit, transferring the marked components onto a separate manufacturing section stage, performing the manufacturing operations, conducting relevant checking procedures which ensure manufacturing compliance with requirements prior to the transfer to the central storage area.

3. A method of manufacturing as claimed in Claim 1 or Claim 2, in which the manufacture of the internal wall panels comprises the steps of cutting head and sill plates and studs to the required lengths; marking the position of the studs and all other horizontal and vertical elements on the head and sill plates; transferring the marked head and sill plates to an assembly line; laying the studs and other horizontal and vertical components on the locations as indicated on the marked heads and sills; installing one or more lifting eyes on the heads; assembling the structure using nailing devices; securing wall panelling to the completed structure with the exception of door openings and window openings by nails and transferring to the central storage area; optionally marking the position of the studs and all other horizontal and vertical elements on the head and sill plates.

4. A method of manufacturing as claimed in any one of Claims 1 to 3, in which the manufacture of the external wall panels comprises the steps of cutting head and sill plates and studs to the required lengths; marking the position of the studs and all other horizontal and vertical elements on the head and sill plates; transferring the marked head and sill plates to an assembly line; laying the studs and other horizontal and vertical components on the locations as indicated on the marked heads and sills; installing one or more lifting eyes on the heads; assembling the structure using nailing devices; securing wall panelling to the completed structure by nails with the exception of door openings and window openings where required, attaching breather paper on the outside wall surfaces by means of rows of staples aligned with studs position; and where required attaching damp proof courses to ground engaging surfaces, and transferring to the central storage area.

5. A method of manufacturing as claimed in any one of the preceding claims, in which the floor panels are manufactured using the steps of cutting the elongate components to the required lengths; marking the location of each joist on the header joist; marking the location of each trimmed joist in relation to the header joist and the parallel trimmer; marking the position of solid blocks on appropriate joists; assembling a floor by laying the header joists on a horizontal surface and laying the joist in correct alignment as indicated on the marked header joist and trimmer, and laying the blocks in relation to the joists; nailing the elements together to form the overall structure; attaching floor sheeting to upper surface of the floor panel, with the exception of openings formed in the floor structure.

6. A method of manufacturing as claimed in any one of the preceding claims, in which the manufacture of the roof assembly trusses comprises the steps of cutting the components to the required length, placing the components on a truss assembly bench, adjusting the bench to suit the particular truss, assembling the truss components using truss plates, placing the trusses into batches and strapping the batches together.

7. A method of manufacturing as claimed in any one of the preceding claims, in which the manufacture of spandrels comprises the steps of cutting the spandrel components to the required dimensions and the approximate angles, marking a soleplate to indicate the location and spacing of components, assembling the components by nailing, if required covering one side of the spandrel with plywood, and also if required applying breather paper to an external surface.

8. A method of manufacturing as claimed in any one of the preceding claims, in which the manufacture of the ladder assemblies comprises cutting the ladder components to the required dimensions to correspond with roof assembly trusses of the house, and assembling the ladder components by nailing.

9. A method of manufacturing as claimed in Claim 8, including manufacturing soffits in the sixth stream of manufacture, including cutting the components to the required size, applying vents to the soffits, staining the soffits and strapping with the assembled ladders for the particular house.

10. A method of manufacturing a timber frame house construction kit, substantially as herein described with reference to the accompanying drawings.

11. A timber frame house construction kit whenever manufactured in accordance with the method as claimed in any one of the preceding claims.

12. An apparatus for manufacture of a wall panel frame, for use in conjunction with the method of manufacturing a timber frame house according to any one of the preceding Claims 1 to 10, the apparatus comprising a longitudinal beam for supporting a foot rail and a longitudinal beam for supporting a head rail, respectively, of the wall frame, and a transverse beam which is located between the two longitudinal beams and, substantially perpendicular to each longitudinal beam, the transverse beam being telescopic so that the head and foot beams are moveable relative to each other, further wherein the transverse beam includes at a position along its length an intermediate stud clamping means for clamping the stud along its length while it is being operated on by the apparatus, the stud clamp applying pressure on the stud forcing the stud to abut a stud locator plate positioned below the stud and wherein the transverse beam also carries an auxiliary control station to allow the operator to control the manufacture process and further wherein the transverse beam also carries a door head guide.

13. An apparatus according to Claim 12, wherein an apparatus for cutting a groove in the or each stud is also provided at a position along the length of the transverse beam, whereby in use the apparatus cuts a groove in the or each stud, having dimensions corresponding to a centre bridging rail so that the groove on the or each stud can accommodate the centre bridging rail therein.

14. An apparatus according to any one of Claims 12 or 13, wherein means are provided to change the relative position of any one of the tools provided along the length of the transverse beam.

15. An apparatus according to any one of Claims 12 to 14, wherein each longitudinal beam is provided with at least one of the devices selected from the following: rail locating device for locating the head rail and foot rail correctly so that the respective leading edges are aligned with the leading face of the first stud; rail clamping device for engaging with a pivoting end clamp device of a stud frame index means.

16. An apparatus according to Claim 15, wherein the rail locating device comprises a rail locator hydraulic ram moveable between an operation position in which the ram abuts with the rail and an inoperational position in which the ram is retracted away from the rail.

17. An apparatus according to Claim 16, further including clamping means for clamping the rails at an input side of the apparatus, the clamping means including clamping rams, a fixed clamp plate and a moveable clamp plate, whereby in use, the rail is located between the fixed clamp plate and the moveable clamp plate and when the clamping rams are activated the moveable clamp plate is urged against the rail so that the area is sandwiched between the moveable clamp plate and the fixed clamp plate.

18. An apparatus according to any one of the preceding claims further comprising an input conveyor means for carrying a wall panel frame towards the apparatus and an output conveyor means for carrying a wall panel away from the apparatus.

19. An apparatus according to any one of the preceding claims, wherein the transverse beam supports at each end thereof a nailing tool for nailing a stud to the foot rail and to the head rail, respectively.

20. An apparatus for manufacture of a wall frame according to claim 12, substantially as herein described with reference to and as shown in the accompanying drawings.