US3297065A - Apparatus for fabricating door assemblies - Google Patents

Description

W. J. ZENNER 3,297,065

APPARATUS FOR FABRICATING DOOR ASSEMBLIES Jan. 10, 1967 '7 Sheets-Shea t. 1

Filed Jan. 21, 1965 INVENTOR.

mi 7% V Jan. 10, 1967 V w. J. ZENNER I 3,297,065

INVENTOR. WALTER J. ZE/V/VER BY M w W FHHEA Jan. 10, 1967 w. J. ZENNER APPARATUS FOR FABRICATING DOOR ASSEMBLIES '7 Sheets-Sheet 5 Filed Jan. 21, 1965 MN wk Wu K ,wvE/vmR WALTER J, ZE/V/VE/P Jan. 10, 1967 w. J. ZENNER APPARATUS FOR FABRICATING DOOR ASSEMBLIES Fil ed Jan. 21; 1965 '7 Sheets-Sheet 4 mmw m3 1 :5 5 m #S QT? K m&

INVENTOR. W/JL TER J. ZE/V/VEH Jan. 10, 1967 w. J. ZENNER APPARATUS FOR FABRICATING DOOR ASSEMBLIES Filed Jan. 21, 1965 'T Sheets-Sheet 5 24 IN III M 5 R mm H W EA V F WZ VJ V m m W B 2 7 I12 2 Jan. 10,1967 w. J. ZENNER APPARATUS FOR FABRICATING DOOR-ASSEMBLIES 7 Sheets-Sheet 6 INVENTOR WALTER J ZEN/V55 Filed Jan. 21, 1965 wmwmL Jan. 10, 1967 w. J. ZENNER APPARATUS FOR FABRICATING DOOR ASSEMBLIES Filed Jan. 21, 1965 7 Sheets-Sheet v' F1 /6 507 308 LI 275 INVENTOR. WALTER J- ZE/V/VER ;:385 EMERG. STOP Unit atent Patented Jan. 1%, i957 nice Walter .i. Zenner, i776 Sherwood Ave, Des liaines, it'll. @3016 Filed .l an. 21, 1965, her. No. 426,974) iii Claims. ill. lad-2'7) This invention relates to a new and improved method of manufacturing door assemblies and to a new and improved automatic routing and drilling machine for fabricating door assemblies. More specifically, the method and the automatic machine of the invention provide improved precision and versatility in routing and drilling a door and a pair of jambs, in a single operation, to afford the requisite receptacles for the door hinges and for a complete lockset.

The hanging of doors has traditionally been one of the more tliffiCLlll and demanding tasks of the finish carpenter. Working by hand, the carpenter cuts into one longitudinal edge of the door to afford shallow receptacles for three hinge plates. Matching receptacles must be provided in the door jamb upon which the door is hung. Either before or after the door is hung, a lockset is mounted in the door. A bolt receptacle is then cut, in the other jamb, on the opposite side of the door opening from the jamb on which the door is hung, and a striker plate is mounted on the receptacle. This is a time-consuming and exacting job and requires a skilled carpenter if the door is to hang and swing properly.

More recently, efforts have been directed toward automation of the fabrication of door assemblies to eliminate the necessity for the precision on-the-job carpenter work previously entailed in the hanging of doors. At least one commercial machine has been produced that routs the hinge edge of the door to afford a series of hinge receptacles, routs the hinge jamb to provide corresponding hinge receptacles therein, drills the door for a lockset, and drills the lock jamb to provide a bolt receptacle and striker plate receptacle. Such equipment, as heretofore known, however, has been relatively expensive and is not economically feasible for relatively small contractors. Moreover, adjustments of the equipment to provide for variations in door width, door thickness, and door height have been relatively complex and time-consuming It is a principal object of the present invention, therefore, to provide a new and improved automatic routing and drilling machine for forming hinge iplate receptacles, lockset receptacles, and a striker plate receptacle in a door and a pair of door jambs, together constituting a door assembly, all in a single operation.

A particular object of the invention is to provide a new and improved automatic routing and drilling machine for the fabrication of door assemblies that can be quickly and conveniently adjusted to accommodate a wide Variety of standard door widths, lengths, and thicknesses. Further, it is an object of the invention to provide equal flexibility in operation of the automatic drilling and routing machine for doors that are to be hung for left-hand or right-hand opening.

Another principal object of the invention is to provide a new and improved method for processing door assemblies in which the three basic members of the door assembly are all held in fixed position relative to each other during the complete drilling and routing operation. The alignment of the door assembly components provided by the method of the invention, and utilized in the machine of the invention, affords a convenient work arrangement with no drills or routers located above the work to interfere with initial positioning of those components.

Another object of the invention is to aliord an improved method, and an automatic routing and drilling machine, for the fabrication of door assemblies, having complete flexibility with respect to variations in door dimensions and in the direction olf hanging of the door with minimum adjustment in the routing mechanism employed to rout out the hinge plate receptacles in the door and in the hinge jamb.

Another object of the invention is to provide an automatic drilling and routing machine for sin gle-operation processing of door assemblies in which adjustments of the lockset drilling mechanism are limited to those necessary for variations in door width and thickness. That is, the machine requires no adjustment with respect to the lockset drilling apparatus as a result ofchanges in door height or changes in the side from which the door is to be hung.

A particular object of the invention is to afford a complete automatic routing and drilling machine for singleoperation processing of a door assembly that inherently provides precise alignment of the lockset bolt receptacle in the door and of the striker plate receptacle in the jamb.

An important object of the invention is to afford a new and improved automatic drilling and routing machine for sin gle-operation processing of door assemblies that is simple and inexpensive yet provides a relatively high output.

Other and further objects of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings which, by way of illustration, show a preferred embodiment of the machine of the present invention and illustrate the principles of both the method and the machine, illustrating what is now considered to be the best mode contemplated for applying these principles. Other embodiments of the invention embodying the same or equivalent principles may be made as desired by those skilled in the art without departing from the present invention.

In the drawings:

FIG. 1 is a perspective view of a right-hand door assembly of the kind processed by the automatic drilling and routing machine of the present invention;

FIG. 2 is a perspective view illustrating the relative positions of the two door jambs and the door of a righthand door assembly during processing ,in the automatic drilling and routing machine of the invention;

FIG. 3 is a sectional view of the door assembly components as positioned during processing taken approximately along line 3-3 in FIG. 2;

FIG. 4 is a sectional view of a completed door assembly, like that of FIG. 1, illustrating the assembling of the components after vfabrication;

FIG. 5 is a perspective view illustrating the components of a left-hand door assembly positioned for processing;

FIG. 6 is a perspective view of an automatic routing and drilling machine constructed in accordance with a preferred embodiment of the present invention;

FIG. 7 is an elevation view, on an enlarged scale, partly in cross-section, of the left-hand portion of the routing head of the automatic drilling and routing machine of FIG. 6;

FIG. 8 is a detail sectional view of a clamp mechanism, taken approximately along line 8-3 in FIG. 7;

FIG. 9 is a detail sectional elevation view showing a portion of the router operating mechanism for the routing head, taken approximately along line 9-9 in FIG. 6;

FIG. 10 is a detail sectional elevation view taken approximately along line 1til0 in FIG. 7;

FIG. 11 is a detail sectional elevation view taken approximately along line 11-11 in FIG. 9;

FIG. 12 is a detail sectional elevation view taken approximately along line l212 in FIG. 9;

FIG. 13 is a transverse sectional elevation view of the lockset drilling head of the machine taken approximately as indicated by line 1313 in FIG. 6;

FIG. 14 is a partially cut-away side elevation view of the lockset drilling head of the machine;

FIG. 15 is a longitudinal sectional view of the drilling head showing the drill mechanisms; and

FIG. 16 is a detail circuit diagram of the electrical control system for the machine.

FIG. 1 illustrates a door assembly 20 that is typical of the type of door assemblies processed by the method and apparatus of the present invention. Door assembly 20 comprises two vertical frame members or jambs 21 and 22 and a transverse upper horizontal frame member 23. A door 24 is included in the door assembly and is hung upon the left-hand jamb 21. Door assembly 20 is of the kind conventionally referred to as a right-hand door. That is, looking toward the door from the side of the frame 21-23 on which the door is hung, as in FIG. 1, the door is hinged on the left-hand jamb 21 and when closed locks with the right-hand jam'b 22. For convenience, jambs 21 and 22 are sometimes referred to hereinafter as the hinge jamb and the lock jamb respectively.

When assembled, as shown in FIG. 1, door assembly 20 is provided with three hinges 25, 26 and 27 by which door 24 is hung on hinge jamb 21. A lockset 28 is mounted in door 24 and includes the usual bolt 29 projecting outwardly of the free vertical edge 31 of the door. Bolt 29 is aligned with and engageable in an appropriate receptacle in the lock jamb 22, this receptacle being provided with an appropriate strike plate 32.

FIG. 2 illustrates the manner in which the principal components of door assembly 20, comprising jambs 21 and 22 and door 24, are aligned with each other for drilling and routing in accordance with the present invention. As shown in FIG. 2, door 24 is supported in a given fixed plane; it should be emphasized that members 21, 22 and 24 remain in the position shown in FIG. 2 throughout the drilling and routing operations described hereinafter. The hinge jamb 21 is mounted in flush alignment with one longitudinal edge 33 of door 24, this being the edge of the door that is to receive the hinges 27. The alignment is such that the edge 34 that is to be the lower edge of the door 24- is disposed a very short distance inwardly from the lower edge 35 of hinge jamb 21. The upper edge 36 of the door is located immediately adjacent a rabbet or slot 37 in the hinge jam-b 21 that later receives the upper frame member 23 of the door assembly (FIG. 1). As shown in FIG. 2, during processing the hinge jamb 21 is aligned with door 24- but is disposed in a plane normal to the plane of the door so that the surface 38 of jamb 21 that is to receive the hinges for the door is flush with the edge 33 of the door on which the hinges are mounted.

The lock jamb 22 is supported immediately above the hinge jamb 21 and in parallel alignment therewith. The rabbet or slot 39 in jamb 22 that subsequently receives the upper frame member 23 is directly aligned with the corresponding slot 37 in jam'b 21.

With the door assembly components 21-23 mounted in the position shown in FIG. 2, a series of routing and drilling operations are performed thereon without movement of the door assembly components. Routers are utilized to out three hinge plate depressions or receptacles 41, 42 and 43 in the longitudinal edge 33 of door 24. At the same time, three corresponding hinge plate receptacles 51, 52 and 53 are formed in the hinge jamb 21 and more specifically in the surface 38 thereof that is aligned with the hinge edge 33 of door 24. The two mating hinge plate receptacles 41 and 51 are routed out in a single routing operation and this is true of the remaining pairs of hinge plate receptacles.

Near the edge 31 of door 24, an aperture 55 is drilled through the door to receive the cylinder for the lockset 28 (FIG. 1). As indicated in FIG. 2, the aperture 55 for the lockset cylinder is displaced by a distance D from the centerline of door 24, the centerline being indicated at 56. The reason for the displacement D is that it is traditional to locate the door handle somewhat below the vertical midpoint of the door.

Two additional drilling operations are performed on the components of the door assembly while aligned in the positions indicated in FIG. 2. A lockset bolt receptacle 57 is drilled in the edge 31 of door 24 to receive the bolt for the lockset. The bolt receptacle 57 communicates directly with the cylinder aperture to permit mechanical interconnection of the bolt and cylinder port-ions of the lockset. In addition, a strike aperture or receptacle 58 is drilled in the lock jamb 22 at the upper edge thereof. It should be noted that the axis of strike aperture 53, which affords a receptatcle for the projecting portion of the lockset bolt and for the striker plate, the axis of cylinder aperture 55, and the axis of bolt aperture 57 all lie in a common plane identified by the intersecting phantom lines 61 and 62. The sectional view of FIG. 3 is taken approximately along this plane and shows the aligned relation of the several receptacles to be fitted with the lockset.

A comparison of FIGS. 3 and 4 shows the convenience and accuracy with which the jambs 21 and 22 and the door 24 may be assembled. As shown therein, the lock jamb 22 is aligned with the edge 31 of the door so that the bolt 29 of lockset 28 projects into the bolt extension receptacle 58. The hinge jamb 21, on the other hand, is rotated through an angle of 180 so that the hinges can be mounted in the mating receptacles, such as receptacles 42 and 52, to hang door 24 on frame member 21.

FIG. 5 illustrates the alternate alignment that is employed for fabrication of a left-hand door assembly. As before, the door 24A is supported in a given plane and the hinge jamb 21A is aligned with the hinge edge 33A of the door. In this instance, however, the rabbeted end of jamb 21A that is to receive the upper horizontal element of the door frame is located at the righthand end of the door as illustrated in FIG. 5 instead of at the lefthand end. As before, the lock jamb 22A is directly aligned with the hinge jamb 21A with the rab beted portions of the two frame members aligned with each other. The two frame members are again located in a plane normal to the plane of the door. As before, the bolt and cylinder apertures for the lockset are displaced by a distance D from the centerline 55A of the door. In this instance, the left-hand edge 34A is the bottom of the door and the displacement D is from centerline 56A toward edge 34A. In all other respects, the alignment employed for a lefthand door, as illustrated in MG. 5, is essentially identical with that for a right-hand door as described above in connection with FIG. 2.

FIG. 6 illustrates an automatic routing and drilling machine 6%) in which the routing and drilling techniques and the positioning of the door assembly components described hereinabove in connection with FIGS. 1 through 5 are directly utilized. Thes machine 60 is of T-shaped configuration, the cross-bar of the T comprising a routing head generally designated by numeral 61. Routing head 61 includes means for clamping the door jam- bs 21 and 22 in working position and means for performing the required hinge receptacle routing operation thereon. This same portion of the machine also includes the drill for forming strike receptacle in lock jamb 22. The leg of the T terminates in a lockset drilling head 62. Routing head 61 and drill head 62 are mounted upon a suitable rigid frame supported upon the legs 63.

The apparatus employed to support the hinge edge of hand edge as seen in FIG. 6, engages a pin 66 that is rigidly but removably mounted in shelf The lower edge of door which is the lefthand edge as seen in FIG. 6, is engaged by a further pin 67 that projects upwardly from. shelf 64.

Pin 67 is not rigidly mounted in shelf 64; rather, a resilient mounting arrangement is employed that permits limited movement of the pin longitudinally of the shelf. This mounting arrangement is best illustrated in FIGS. 7 and 8. As shown therein, pin 67 is mounted in an aperture in a slide block 69 disposed within the interior of shelf 64. The upper end of pin 67 projects outwardly through an elongated slot 71 in the upper side of the shelf. Slide block as is connected to a spring 72 that pulls the slide blocl; toward the right as seen in FIGS. 6, 7 and 8.

At the time an operator positions a door 24 in machine on, that portion of locks-ct drilling head 62 which engages the door is displaced to a position clear of the door location in the machine, as is described more fully hereinafte With the lockset drilling head thus clear of the door location, door 24 is moved into position from the right-hand side of the machine, as seen in MG. 6, with the side of the door adjacent the hinge edge resting upon shelf 64 but with the door held above pin on. Edge 34- of the door is brought into engagement with pin 67 and the operator pushes longitudinally against the door until pin 67 is deflected to the left through a distance sufficient to clear the upper edge 36 of the door over pin 66. The door is then dropped into position on shelf 64, the spring bias against pin 67 pulling the door back firmly against pin 66. In this manner the door is accurately positioned in the machine and is ready for processing, once the clamp devices described hereinafter in connection with mechanisms 6t and 62 are brought to bear thereon.

The relative positions used for pins 66 and 67 are dependent upon the desired length of the door. For example, the pins may be positioned as shown for processing a standard six foot eight inch door assembly that comprises a right-hand door. If a taller door is required, as for example a conventional seven foot door, then the fixed pin 66 may be moved to an alternate receptacle to achieve the desired accurate positioning of the door in the machine. One such alternate pin receptacle 74 is shown in FIG. 6; additional receptacles for further standardized door heights may be provided if required. The slide pin 67 does not require a change to compensate for variations in door height.

When the machine 60 is to be employed in processing a lefehand door, the pins as and 67 are reversed with respect to their functions. Referring to FIGS. 7 and 8, it is seen that the left-hand end of the channel shelf 64 is provided with two pin receptacles 75 and 76. If a lefthand door of standard six foot eight inch height is to be processed, pin 67 is removed from slide block 69 and placed in receptacle 75 where it serves as the fixed base pin for locating a door in the machine. if a seven foot door is to be processed, pin 67 is placed in receptacle 7d. The adjustment of the machine for processing of a lefthand door, as regards positioning of the door in the machine, is completed by removing pin as from its fixed position as shown in PEG. 6 and replacing this pin in a slide block (not shown), like slide blocl; 69, that is located in the right-hand end portion of shelf 64. The loading technique for placing the door in the machine is the same as described above except that the operator works from the left-hand side of the machine instead of the right-hand side.

Near the right-hand end of routing head 61, as seen in FIG. 6, a rigid but removable jamb stop 77 is mounted upon and projects outwardly of the front face of the router head. With the door 2.4 in place, as described above, the machine operator slides the hinge jamb 211 across the top surface of the door but clear of the fixed jamb stop 77 and into engagement with a spring biased d sliding jamb stop 73 that is located at the opposite end or" router head till from stop 77.

As shown in FIGS. 7 and 8, the sliding jamb stop '73 is mounted upon a shaft 79 that extends through an elongated slot 89 in the face plate and into a soclret or receptacle in a slide block hi that is mounted upon the inner surface of the face plate. Slide block 81 is supported upon a pair of studs 82 that are atfixed to the router head face plate 65. Studs 32 engage in elongated slots 83 in the slide block so that the slide block is permitted a substantial degrees of movement of the left and to the right as seen in FTC-S. 6 and 8. A spring 84 is connected to slide block 81 and biases the slide block to the right. It is thus seen that s ring 34 is effective to bias the slidable jamb stop 78 toward the fixed jamb stop 77 at the other end of the router head.

The machine operator pushes the jamb 21 against slidable jamb stop 7%} and moves the slidaole jam stop to the left through a distance sufiicient to enable him to engage the fixed jamb stop 77 in the slot 37 that ultimately receives the upper frame member 23 of the door assembly (see FIGS. 1 and 2). The flared end portion hr: of the movable jamb stop 78 (FIGS. 68) permits initial insertion of jamb 21 into the machine at an angle so that the foregoing operation can be carried out quickly and conveniently. An inwardly projecting pin 37 on jamb stop 73 engages the edge of jamb 21 and holds the jamb firmly in aligned longitudinal position.

The same technique is followed by the operator in mounting the lock jamb 22 in machine 60. That is, the operator slides lock jamb 22 into position on top of hinge jamb 22 and then moves the lock jamb toward the face place 65 to bring the fixed jamb stop 77 into locking engagement in the rabbet or slot in the jamb member. Lock jamb 22 is engaged by an inwardly projecting pin 88 on the slidable jamb stop 78 and thus is held firmly in position. A wear plate 87 may be provided upon the face plate 65 of router head 61, behind the jambs, to protect the face plate against abrasion from movement of the jambs into and out of the machine.

For a taller dor, it is necessary to adjust the position of the fixed jamb stop 77. This is accomplished simply by removing the fixed jamb stop from face plate 65 (FIG. 6) and re-mounting the same at the required position for the longer door. In the illustrated embodiment, face plate 65 is provided with a pair of tapped openings 91 or other siutable mounting elements to permit quick and convenient re-mounting of the fixed jamb stop 77 in position for a taller standard door.

For processing of a left-hand door, the conversion of the jamb-mounting apparatus is as simple as that for the door-positioning apparatus. The slidable jamb stop 73 is removed from slide block 31 (FIG. 8) by pulling the jamb stop shaft 79 outwardly of the slide block through slot 8d and is then repositioned in a similar slide block (not shown) located near the right-hand end of the router head. To mount the jarnbs on the machine, the same technique is followed as described above for a right-hand door except that the operator works from the left-hand side of the machine and engages the rabbetted or slotted portions of the jambs with a rigid jamb stop 93 located at the left-hand side of the machine. The mounting position for the jambs is illustrated by the dash outline 22C in FIG. 8. For complete flexibility, with respect to door height, one or more alternate mounting positions for the rigid jamb stop 93 may be provided at the lefthand side of the machine as shown in M05. 7 and 8.

Machine 6d, as thus far described, positions the door 24 and jambs 2t and 22 in longitudinal alignment, with the two jambs disposed in a plane perpendicular to the plane of the door .24 and in alignment with the hinge edge of the door. For processing of the jambs and of the hinge edge of the door, however, it is essential that the workpieces be prevented from moving vertically. It

is also necessary to restrain the jambs against horizontal movement outwardly of face plate 65. Two interconnected clamping and restraining devices 101 and 1&2 are employed for this purpose (FIG. 6). Inasmuch as the two clamping devices 101 and 162 are essentially identical in construction, only the device 101 is shown in detail in the drawings.

As illustrated in FIG. 6, a clamping rack 103 extends across the face of router head 61 in alignment with the two jambs 21 and 22. Rack 1113 comprises a pair of elongated bars or pressure members 104 and 1115 interconnected at spaced points by three cross bars 106, 1117 and 108. A central bar 109 is incorporated in the rack 103 and extends parallel to pressure bars 1114 and 105'. The long bars 1114, 105 and 1119 are all welded or otherwise rigidly secured to cross bars 106, 107 and 1118 to afford a rigid rack assembly.

The clamping and retaining mechanism 101 comprises a vertically extending arm member 111, the lower end of which is rigidly afiixed as by welding to the central bar 1119 in the rack assembly 103. The upper end of arm 111 is affixed to a lever 112 that projects through an opening 113 in the face plate of routing head 61. Lever 112 is pivotally mounted on a suitable shaft or pivot pin 114 as shown in FIGS. 7, 9 and 10. Shaft 114 is mounted in a bracket 115 extending downwardly from the top plate 116 of routing head 61.

Lever 112 includes a downwardly extending lug 117 that is pivotally connected by a pin 118 to a link 119 (FIGS. 9 and Link 119, in turn, is pivotally connected by a suitable pin 121 to a crank 122 affixed to one end of an actuator shaft 123. Shaft 123 is rotatably driven by an electrically operated actuator mechanism 124 that is described more fully hereinafter. For the present, it is sufficient to note that actuator 124 comprises a small electric motor that rotates shaft 123 through an angle of 180 each time the motor is energized. Actuator 124 is provided with a second shaft 125 that is a continuation of shaft 123 and that is used to drive the other clamping and retaining device 1112 (FIG. 6).

In FIGS. 6, 7, 9 and 10, the clamping apparatus comprising devices 1111 and 1112 is shown in clamping position. In this position, the upper bar 1115 of rack 1113 presses against lock jamb 22 and holds the jamb firmly against the wear plate 89 on the front face 65 of routing head 61. Similarly, the lower bar 1114 of the pressure rack presses against hinge jamb 21 and maintains the hinge jamb in firm engagement with the wear plate. A pressure clog 127 that is mounted upon arm 111 of clamping device 1111 engages the top edge of lock jamb 22 and presses the two jamb members and the door 24 downwardly into firm engagement with shelf 64. A simi lar pressure dog 128 in device 1112 (FIG. 6) also presses downwardly, pushing the two jamb members and the door into firm engagement with shelf 64-. Thus, with the clamping system comprising devices 1111 and 1122 and rack 1113 in the position shown in the drawings, the two jamb members are firmly held against lateral movement away from wear plate 83 on the face of the routing head 61. The jamb members and door 24 are also held against vertical movement, being pressed downwardly into firm engagement with shelf 64.

To remove the door and the jambs from the routing head at the end of their processing, actuator 124 is energized and rotates shafts 123 and 125 through an angle of 180. As a consequence, and through the linkage provided by crank 122 and link 119, lever 112 is rotated in a clockwise direction as seen in FIG. 10. This pivots the left-hand end of lever 112 upwardly and away from the jambs 21 and 22. A similar operation takes place simultaneously at the other clamping device 102 (FIG. 6), which is actuated simultaneously through the shaft 125 (FIG. 9). The pivotal movement of lever 112 releases dog 127 from engagement with the top edge of jamb 22 and the corresponding movement in the other clamping device 102 releases dog 128 from engagement with the &

lock jamb. Simultaneously, rack 103 is lifted upwardly and outwardly with respect to the two jamb members so that the pressure bars 104 and are disengaged from jambs 21 and 22 respectively. It is thus seen that the energization of actuator 124 releases both of the clamp ing devices 161 and 102 and frees the two jamb members and the door for removal from the machine.

When the processed door and jambs have been removed from the machine and a new door and jambs are placed therein as described above, actuator 124 is energized, at

the beginning of a processing cycle, and again rotates shafts 123 and through one-half revolution. The operating linkages of the two clamping devices 101 and 102 are thus actuated to return the clamping apparatus to the position shown in drawings, with the rack 103 pressing the two jambs against wear plate 89 and with the dogs 127 and 128 pushing the jambs and the door downwardly into firm engagement with shelf 64.

The principal function performed by routing head 61 is the routing of the three sets of hinge receptacles in the edge of door 24- and in the surface of hinge jamb 21. The routing mechanism is best illustrated in FIGS. 9 and 11. It should be noted that FIG. 9 shows only slightly more than one-half of the routing head and that the other half is an essential duplicate thereof; the same is true with respect to FIGS. 7 and 8.

The routing mechanism of routing head 61, as shown in FIGS. 9 and 11, comprises a first elongated frame 131 that extends the full length of the routing head. This first frame 131 comprises a pair of vertical frame mem bers 132; only the one frame member 132 is illustrated in FIG. 9, the corresponding vertical frame member being located at the opposite end of routing head 61. These two vertical frame members are joined near their lower ends by a transverse frame member 133 that is rigidly aflixed to each of the two vertical frame members. The upper end of each vertical frame member 132, as illustrated in FIG. 9, is pivotally mounted upon an elongated guide shaft 134 suspend-ed from the top plate 116 of routing head 61 by suitable means such as a pair of brackets 135. A similar mounting arrangement, including a similar guide shaft, is used for the other vertical frame member (not shown) at the opposite end of the routing head. it is thus seen that the complete frame 131 can pivot about the axis of the guide shafts 134 toward and away from the face plate 65 of the routing head 61.

As shown in FIGS. 9 and 11, the lower end of vertical frame member 132 is pivotally connected to one end of a link 137. The other end of link 137 is pivotally connected to a crank 138 that is fixedly mounted on the end of a drive shaft 139. Shaft 1.39 is driven by an electrical actuator 141, the actuator 141 including a second shaft 142 that extends across the routing head to the other vertical frame member and is connected thereto by a linkage (not shown) similar to that comprising crank 138 and link 137.

An elongated guide rod 143 is fixedly mounted upon the transverse frame member 133 of frame 131 and extends between the vertical frame member 132 and a bracket 144 that is mounted upon frame member 131. A corresponding guide rod, not shown, is provided at the opposite end of the routing head, extending parallel to the other end portion of transverse frame member 133. Guide rod 14-3, together with shaft 134-, is employed to support and to guide horizontal movements of a second frame 146 that is incorporated in the routing mechanism of the machine.

Frame 1 16 includes a pair of parallel elongated transverse frame members 147 and 149 that extend throughout substantially the full length of routing head 61. One end of frame member 147 is rigidly affixed to a vertical frame member 1 as shown in FIG. 9. The opposite end of frame member 147 is rigidly secured to a similar vertical frame member (not shown) at the opposite end of the ii routing head. Vertical frame member 148 is slidably engaged on each of the twoguide rods 134 and 143, and a similar arrangement is used at the opposite ends of the routing head. Thus, the complete frame 146 is mounted for sliding movement in a direction indicated by the arrows X in FIG. 9. The other transverse frame member 149 extends parallel to frame member 1 17 and is affixed to the vertical frame members, such as frame member 148, at the medial portions thereof. Additional vertical braces 159 may be provided in frame 146.

An electrically driven actuator 151 is provided for frame 146. The drive shaft 152 of actuator 151 carries a crank 153 that is pivotally connected to a link 154-. Link 154 in turn is pivotally connected to one end of an elongated lever 155. A pin 156 mounted on the other end of lever 155 fits into a socket in the lower transverse member 147 of the second frame 146, pivotally connecting lever 155 to frame 146. The mechanism is shown with the linkage 153-155 at the mid-point of an operating cycle because illustration of the apparatus at either end of its operating cycle would cause lever 155 to obscure part of the connections for the transverse frame member 147 (FIG. 9). It should be understood that completion of an operating cycle for actuator 151 would rotate shaft 152 through an angle of 90 from its illustrated position and that a complete half-revolution cycle of the actuator moves frame 146 through a predetermined distance horizontally as indicated by the arrows X.

There is a further router positioning frame 161 in routing head 61 that is connected to frames 131 and 146, these three frames conjointly operating to define an operating cycle for the routing devices as described hereinafter. This third frame 161 comprises two elongated frame members 162 and 163 that extend substantially the full length of routing head 161 and that are joined to each other by a series of three router mounting plates. Two of these router mounting plates 164 and 165 are shown in FIG. 9; it should be understood that there is a third such mounting plate located in the right-hand portion of the routing head in a position similar to that illustrated for plate 164.

The third positioning frame 161 is driven by an electrically powered actuator 168 comprising a motor having two output shafts 169 and 171. Actuator 168 is mounted upon the upper transverse frame member 149 of frame 146. The end of shaft 169 opposite the actuator projects through and is supported by a bearing 172, the bearing mounted upon frame member 149. The end of the shaft 169 carries a crank 173 that is .pivotally connected to one end of a link 174. The opposite end of link 174 is pivotally connected to the end of the upper transverse frame member 163 of frame 161. A similar linkage (not shown) is utilized at the opposite end of the machine to connect shaft 171 to frame member 163.

As illustrated in FIGS. 9 and 11, the actuating mecha nism for frame 161 is at one end of its operating cycle. A first complete operating cycle for actuator 168 rotates shafts 169 and 171 through an angle of 180 and moves the complete frame 161 upwardly through a predetermined distance. In a second operating cycle, actuator 168 again rotates the actuator shafts through 180 and moves frame 161 downwardly through the same distance. It is thus seen that actuator 168 drives frame 161 through a predetermined vertical distance, as indicated by the arrows Y, in each cycle of its operation.

There are six router openings located at spaced intervals across the face plate 65 of router head 61. In FIG. 9, three such openings 181, 182 and 163 are shown. It should be understood that there are three additional router openings (not shown) located to the left of that portion of the routing head that is illustrated in FIG. 9. Three individual routers are incorporated in the routing head 61, two of these routers 184 and 185 being shown in FIG. 9. The third router for the machine is located to the left of router 135 as shown in FIG. 9 and is disltd placed therefrom by a distance equal to the spacing between routers 184 and 185.

To rout the three sets of hinge cavities or receptacles in door 2-1 and in hinge jamb 21 as described hereinabove in connection with FIG. 2, it is necessary to move the three routers such as routers 184 and in three direct-ions. Initially, the routers are advanced from a retracted position displaced from the workpieces to an engaged position in which each router cuts into the Wood workpieces as shown in FIG. 11. This advancing movement toward the workpieces is accomplished by pivotal movement of frame 131 effected by actuator 1 11.

Once the three routers are advanced to cutting position by actuator 141, they are moved through. a rectangular path, in a vertical plane, to rout out the desired substantially rectangular hinge plate cavities. The initial vertical movement is accomplished by energizing actuator 16 8 to move the routers upwardly, this movement being effected by upward movement of frame 161 as indicated by the arrows Y. When the initial upward movement has been completed, actuator 151 is energized to move the routers horizontally through a given distance as indicated by the arrows X. Actuator 168 is then energized to drive the actuators, through frame 161, back downwardly to their original level. Actuator 151 is then energized to move frame 146 back in a horizontal direction to their initial position. Finally, actuator 141 is energized. to rotate shaft 142 through a further 180 cycle and retract the complete assembly of three routers by pivotal movement of frame 131.

The router frame mechanism, as illustrated in FIG. 9, is set up for a standard six foot eight inch left-hand door. To compensate for the different length of a seven foot door, the connection between lever 155 and frame member 1147 may be changed by removing pin 156 from its illustrated connection to the frame member and inserting the pin in a further socket 188. This compensation is not absolutely essential if some assymmetry' is permissible in the hanging of the seven foot door, but is relatively easy to accomplish if complete symmetry is desirable.

When the machine is to be employed for processing of right-hand door assemblies, it is necessary to re-position the routers. The need for this change is apparent when it is considered that the door and jamb members are mounted differently in the machine for left and right-hand doors (and in View of the off-center alignment of the lockset receptacles in the door, all as described above. To condition the machine for processing of a six foot eight inch right-hand door, pin 156 is connected into a different socket 189 in frame member 14-7. This change shifts the complete frame 166 a substantial distance to the left as seen in FIG. 9 and aligns router 184 with opening 182 in face plate 65 instead of with opening 181 as shown. A similar re-alignment takes place with respect to the remaining two routers of the machine. Again, compensation for a seven foot door may be accomplished by changing the connection of the pin 156 to an additional socket 191 in frame member 14 7. The router openings such as openings 181-183 are made Wide enough to avoid interference with the routers whether operating on six foot eight inch doors or seven foot doors.

The routing and drilling head 61 also includes the mechanism for drilling the strike receptacle: $8 (FIGS. 2 and 3) in lock jamb 22. The drilling mechanism employed for this purpose is best shown in FIGS. 9 and 12. As shown therein, a bracket 195 is mountedat the center of face plate 65 in the upper portion of the face plate. Bracket 195' is secured to face plate 65 by a clamp screw 196 that extends through an elongated narrow slot 197 in the face plate (see FIGS. 7 and 12) and is threaded into the bracket. The lower end of bracket i195 is provided with an elongated slot 198 that receives a pin 199. Pin 199 is afiixed to and projects inwardly of face plate 65 and is utilized to guide bracket 195 and to maintain the bracket in fixed vertical alignment on the face plate.

Bracket 195 carries a pair of horizontal shafts 201 that are perpendicular to the plane of face plate 65. A yoke 2112 is slidably mounted upon the two shafts 201 and this yoke supports an electrically driven drill 203. Yoke 201 is pivotally connected to one end of a link 204; the other end of the link 204 is pivotally connected to a crank 205 carried by the shaft of an electrically driven actuator 206. Actuator 206, when energized, advances drill 203 to bring the cutting member 207 into engagement with the upper edge to lock jarnb 22 to drill the strike receptacle in the jamb. The cutting element 207 of drill 203 projects through an appropriate opening 208 in the face plate 65 of routing head 61.

In some instances, it may be desirable to change the width of the jambs to suit particular job requirements or for other reasons. Moreover, it is desirable to align drill 2113 quite accurately with respect to the upper edge of jamb 22 to assure precise location of the striker plate receptacle in the jamb. To this end, a gauge member 2111 is incorporated in the mounting arrangement for drill 203. Gauge 210 is affixed to and extends downwardly from a collar 212 through which clamp screw 196 extends. When jamb members of a new standardized width, or of an indeterminate width, are mounted in the machine clamp screw 196 is retracted a distance sufficient to release bracket 155 for vertical movement from its normal clamped engagement with face plate 65. With the clamp screw 196 thus released, the weight of the bracket and drill moves the drill assembly downwardly until gauge member 210 engages the top edge of jamb 22 as shown in FIG. 12. The clamp screw 196 is then tightened and the drill is accurately positioned for forming the desired strike receptacle.

The frame of the automatic routing and drilling machine 60 (FIG. 6) includes a pair of fixed rails 211 and 212 that extend parallel to each other along the leg of the T-shaped machine. Rails 211 and 212 constitute support rails for the lockset drilling head 62 of the machine, which is illustrated in detail in FIGS. 13-15.

A base member 213 (FIG. 14) is suspended from rails 211 and 212. At the outer or left-hand end of base 213 there are a pair of vertical hanger members 214 that project upwardly from the base member. Each of these hanger members 214 is provided with a socket portion 215 that receives an inwardly projecting ledge portion on the respective one of the rails 211 and 212 with which the hanger member is aligned (see FIGS. 13 and 14). In addition, the front or right-hand end of base 213 includes an additional pair of vertical hanger members 216 each provided with a socket portion 217 that encompasses the associated rail and provides further support for the base.

As discussed hereinabove, machine 61) accommodates a wide variety of doors of varying width. To adjust the lockset drill head 62 to a particular door width, the position of base 213 is changed by sliding the base along the parallel support rails 211 and 212. Thus, for a particular door width, the base member is moved longitudinally of the rails to the desired position and a retainer rod 218 is inserted through the appropriate one of a series of holes 219 in rail 212 and through a complementary opening in the vertical hanger member 216 at the front of base 213. Rod 218 extends completely across base 213 and through the vertical hanger member 216 on the opposite side of the lockset drill head, as shown in FIG. 13, and out through an aligned aperture in rail 211. This suspension arrangement locates base member 213 in fixed longitudinal position on the rails 211 and 212.

A main drill carriage 221 is also mounted upon rails 211 and 212 for sliding movement along the rails. Carriage 221 includes a pair of transverse support bars 222 and 223 that project outwardly of the carriage, on the sides thereof, each of these support bars being provided with appropriate slots for engaging and receiving the 12 upper portions of rails 211 and 212. Preferably, stipport bars 222 and 223 have slotted ends engaging both the upper and lower faces of the lip portions of the rails to hold the carriage 221 down on the rails.

Main drill carriage 221, the internal construction of which is described more fully hereinafter, supports a pressure gauge member 224. Variations in the geometry of the lockset may require changes in longitudinal alignment of the pressure gauge member 224 relative to carriage 221, as described more fully hereinafter. Provision for such longitudinal adjustment is incorporated in drill head 62 by connecting member 224 to carriage 221 by means of an elongated retaining rod 225 that extends across the outer end of gauge member 224 and through mating apertures in the gauge member and in the carriage. Pressure gauge member 224 is provided with a series of apertures 226, making it possible to effect the required longitudinal adjustment of members 221 and 224.

An electrically driven actuator 227 is mounted upon the bottom of base member 213. The output shaft 228 of actuator 227 carries a crank 229 that is connected to one end of a link 231, as best illustrated in FIG. 14. The other end of link 231 is pivotally connected to an additional link 232 near the righthand end of link 232 as seen in FIG. 14.

The rear or left-hand end of link 232 is pivotally connected to the upper end of the hanger 214 that is an integral part of base member 213. The right-hand end of link 232 is pivotally connected to a crank-shaped arm 234 that is a part of a pressure yoke 235. The crank arm 234 is pivotally connected to pressure gauge member 224 by a pin 236. The forward or right-hand end of the crank arm is connected to a transverse bar member 237 that extends across the lockset drill head 62 as shown in FIG. 13 and is connected to a corresponding crank arm 238 on the opposite side of the machine. The other crank arm 238 of yoke 235 is connected to a similar linkage on the opposite side of the machine, including a horizontal link 241 and a vertical link 242, the latter being connected back to a crank 243 on the end of actuator shaft 223 opposite crank 229 (see P16. 12). The outer ends of the two crank arms 235 and 238 carry a pair of pressure rollers 246 and 248, respectively, that engage the surface of door 24 to clamp the door in place as described more fully hereinafter.

The left-hand portion of main drill carriage 221 includes a pair of elongated horizontally extending support rods 251 and 252. Rod 251 is a fixed support member, extending from a forward wall 253 of carriage 221 to the rear wall 254 thereof. Rod 252 extends between the same two carriage walls 253 and 254 but is brought out beyond wall 254 and is provided with a handle 255 to permit rotation of the support rod.

Support rods 251 and 252 are utilized to support a bolt drill carriage 256 within the main drill carriage 221. Thus, rod 251 extends through the front and rear walls of the bolt drill carriage 256 and supports the right-hand portion of the carriage, as viewed in FIG. 13, at a fixed vertical position. The left-hand portion of the bolt drill carriage 256 is provided with a pair of rectangular openings, one such openings 257 being illustrated in FIG. 13. These two openings are aligned with support rod 252. A pair of eccentrically mounted polygonal cam support members 258 (shown as rectangular in configuration) are affixed to support rod 252 in alignment with the openings 257 to support the left-hand side of bolt drill carriage 256. This mounting arrangement makes it possible to make minor changes in the height of the drill employed to form the bolt aperture in the door described more fully hereinafter.

An electrically powered actuator 261 is mounted in the lower portion of bolt drill carriage 256 (FIGS. l3 and 15), actuator 261 being provided with an output shaft that carries a spur gear 262. Spur gear 262 is disposed in meshing engagement with a rack 263 mounted upon id a yoke 264. Yoke 264 is slidably mounted upon a pair of. elongated longitudinally extending support and guide rods 265 that extend from the front to the rear of bolt drill carriage 256. Yoke 264 is the support for a conventional electrically powered drill 266; the operating shaft 267 of the drill projects through openings in the front wall of the bolt drill carriage 256 and in the adjacent wall of the main carriage 2.21 in alignment with an opening 268 in the front or right-hand wall of gauge and pressure member 224 as shown in FIG. 15.

At the front or right-hand end of the main drill carriage 221, as seen in FIGS. 14 and 15, there is a downwardly projecting enclosed frame 271. A pair of vertical guide rods 2 72, of which only one is illustrated in the draw logs, are mounted within this portion of the main drill carriage. A yoke 273 is slidably mounted on these vertical guide rods. A rack gear 274 is mounted upon yoke 273 and projects downwardly therefrom into meshing engagement with a spur gear 275. Spur gear 275 is affixed to the output shaft of an additional electrically powered actuator 276 that is mounted within the vertical portion 271 of main drill carriage 2Z1.

Yoke 2 73 supports a conventional electrically powered drill 277 that is utilized to drill out the cylinder opening for the lockset, in door 24-, as explained more fully hereinafter. The operating shaft and cutting head of drill 277 are aligned with a suitable opening 278 in the top of the enclosed frame 271.

The front or right-hand end of the main drill carriage 221, comprising the vertical section 2'71, also carries a wear plate 281. When door 24 is mounted in the ma chine, the door may rest directly upon wear plate 281 and upon shelf 64. As shown in FIG. 15, however, it may be desirable to insert shims 282 and 2% on wear plate 281 and shelf plate 64 to elevate door 24 slightly above the upper surfaces of the wear plate and the shelf. Such shims may be utilized to compensate for variation in door thickness; for example, in a given machine, doors intended for exterior use, and of a first given thickness, may be supported directly upon the wear plate 2551 and upon the shelf 64, whereas somewhat thinner standardized doors for interior use may be mounted upon the shims 282 and 233 as illustrated in FIG. 15.

FIGS. 14 and 15 illustrate lockset drill head 62 in an operating position achieved by the apparatus immediately following the drilling of the bolt aperture 57 and the cylinder aperture 55 in the door. At this point in the operating cycle of the machine, and with the drills 266 and 277 in the position shown, actuator 22) may be energized to rotate its shaft 228 through an angle of 180, pivoting cranks 229 and 243 from the position illustrated in FIGS. 12 and 14-, in which the cranks project directly upwardly, to an alternate operating position in which the two cranks extend directly down from the axis of the actuator shaft. This pivotal movement of crank 22% pulls link 231 to the position generally illustrated by the phantom line 231A (FIG. 14) and thus pivots link 232 in a clockwise direction to the position generally illustrated by the phantom line 232A. This action pulls crank 234 to the left from the position shown in FIG. 14 and also pivots the crank in a counterclockwise direction about its pivot pin 236 so that the general position of the crank is that shown by the phantom lines 234A. As a result, pressure rollers 245 is pivoted upwardly and away from the surface of door 24 to the position indicated by the phantom outline 245A. This releases the edge portion of the door for vertical movement. At the same time that the yoke comprising crank 23 i is thus pivoted upwardly and away from the door, the pressure gauge member 224 moves to the left away from the edge of the door, due to the connection afforded by the pin 236 between the yoke and the pressure gauge member. Accordingly, it is seen that the door is freed for movement horizontally and vertically, enabling the machine operator to lift the door from the machine.

ozone When a new door is loaded in the machine, actuator 227 is again energized to rotate its shaft 228 through rotating cranks 229 and 243 back to the positions illustrated in FIGS. 13 and 14. This drives the linkage 231i, 232 and the pressure yoke 235 back to the position shown in the drawings with the pressure rollers M5 and 248 pressing door 24 downwardly against the wear plate member 281. in this manner, the door is held firmly against vertical movement, in the area immediately adjacent the lockset drill head. At the same time, the connection provided by pin 236 between the pressure yoke 235 and the pressure gauge member 224 moves the pressure gauge member back to the right and brings that member into engagement with the edge of the door as shown in FIGS. 14 and 15.

The next stage in the operation can be the actuation of either the cylinder drill 277 or the bolt drill 266. Assuming bolt drill 266 is to be operated first, then actuator 261 is first energized. The rack and pinion drive comprising spur gear 262 and rack 263 then drives yoke 2nd to the right along guide rods 265 (FIG. 15) to drill the bolt aperture 57 in the door. When this drilling operation is completed, the direction of rotation of actuator 261 is reversed and the drill is retracted to its initial position as shown in FIG. 15.

The next operation is to energize the electrically driven cylinder drill actuator 277. Drill 277 is moved upwardly by the rack and gear drive 274, 2'75 and drills the cylinder aperture 55 in the door. When this drilling operation is completed, continued operation of actuator 276, but with reverse rotation, is effected to retract drill 277 to its original position as shown. This completes the drilling of the door for the lockset; the door can thereafter be released as described above and replaced by another door.

Different locksets may require different lengths for the bolt receptacle 57. Any changes required in this regard may be effected by withdrawing the retaining rod 225 and adjusting the relative positions of the drill carriage 221 and the pressure gauge member 2% by selection of the required retaining rod opening 226 in the pressure gauge member. Because of the relatively large size of cylinder aperture 55 and the relative standardization of bolt lengths, a series of three or four adjustable settings for the pressure gauge member are adequate to permit operation of the machine for a wide variety of different locksets.

It is desirable to have the bolt aperture 57 accurately aligned with the center plane of door On the other hand, changes in door thickness, accommodated by use of the shims 282 and 2835, may change the alignment of the bolt drill shaft 267 with respect to the center of the door when the door is mounted in the machine. This variation in alignment can be effectively compensated by rotation of the support shaft 255 that carries the left-hand portion of. bolt drill carriage 256 (FIG. 12). Thus, the eccentric mounting of the support blocks or cams 258 on shaft 252 makes it possible to effect small variations in the height of the drill 2156 to afford precise alignment of that drill with the center plane of the door.

Adjustment of lockset drill head for variations in door width is a relatively simple matter. To accommodate a door that is substantially narrower than the door 24 illustrated in FIG. 14, retaining rod 23.8 is withdrawn and the complete drill head 62 is moved to the right along rails 211 and 212 to the required position for the narrow door, and the retaining rod 218 is re-inserted through the appropriate aligned holes 12.19 in the rails. The socket holes 219 can be marked for various door widths so that the machine operator is not required to estimate which mounting hole should be used for a door of a given specific width.

FIG. 16 illustrates a preferred form of automatic control circuits for actuating and controlling the complete operations of the machine ed as described hereinabove. That is, the circuit illustrated in FIG. 16 is effective to control the actuation and operation of the electrically driven drills 203, 256 and 277 and the routers 134 and 185 as well as the third router of the machine.

The principal control elements of the machine, all of which are shown in FIG. 16, comprise the actuators 124, 141, 151, 158, 206, 227, 261 and 276, all of which have been described hereinabove with respect to their mechanical connections to the machine and their mechanical functions. Each of these actuators comprises a small electrically driven motor having appropriate field windings and a rotor for driving the actuator shaft. However, there are variations in the actuator construction, depending upon the task to be performed by each actuator.

Thus, the lockset clamp actuator 227 illustrated in the upper right-hand corner of FIG. 16 comprises a small electric motor including a rotor 301 having two field windings 302 and 333 that are connected to each other, the common terminal of windings 302 and 303 being returned to ground. A capacitor 304 is connected across windings 302 and 303. The output shaft 228 of actuator 227 carries a cam 305 that engages and actuates the movable contacts 306 and 307 of two single-pole double- throw switches 300 and 308, respectively. As can be seen from FIG. 16, cam 395 engages movable contact 306 in a first operating position for the actuator, referred to hereinafter as the home position. Rotation of the shaft through 180 causes the cam to engage and actuate the second movable contact 307 of the actuator.

The hinge clamp actuator 124 is similar in construction to actuator 227. Thus, the operating shaft 123 of this actuator drives a cam 309 that actuates the movable contacts 311 and 312 of a pair of single-pole double- throw switches 310 and 313, respectively. In its initial or home position, the actuator cam 309 engages movable contact 311. Rotation of shaft 123 through an angle of 180 brings the cam into engagement with movable contact 312.

The three coordinate actuators for moving the routers to rout out the hinge receptacles, actuators 141, 151 and 168, are of similar construction. Shaft 139 of actuator 141 is provided with a cam 314 that normally engages the movable contact 315 of a first single-pole doublethrow switch 317 but is engageable with the movable contact 316 of a second single-pole double-throw switch 313 upon rotation of the actuator shaft through an angle of 186. Shaft 169 of router movement actuator 168 carries a cam 319. Cam 319 is engaged with the movable contact 321 of a first single-pole double-throw switch 32d when the actuator is in its initial operating position as shown and is engageable with the movable contact 322 of a similar switch 323 upon rotation of the actuator shaft through one-half revolution. The cam on shaft 152 of router actuator 151 is designated by reference numeral 324 and is engaged with the movable contact 325 of a first single-pole double-throw switch 327 when actuator 151 is in its home position. Cam 32 engages the movable contact 326 of a similar switch 322% upon rotation of shaft 152 through an angle of 180.

The strike drill actuator 205 is similar to the actuators described above but somewhat simpler in construction. Thus, the shaft of this actuator carries a cam 329 that normally engages first movable contact 331 of a single-pole double-throw switch 330 to hold that contact in predeter- :rnined position. Upon rotation of the output shaft of :actuator 206, cam 329 is released from contact 331 and permits the contact to move to an alternate position, the contact 331 remaining in its alternate position until a full revolution of the actuator shaft is completed.

The bolt drill actuator 251 and the hinge drill actuator 276 are similar to each other but are somewhat different in construction from the other actuators. Considering actuator 261, it is seen that this device is a small electric motor including field windings 332 and 333 electrically connected to each other with the common terminal of the windings grounded. A capacitor 334 is connected across the two windings. The rotor 335 of the motor drives the spur gf flf 62 ,(see FIG. 15) that meshes with rack 263.

One end of rack 2&3 (FIG. 16) is engaged by a lever arm 338, lever 338 being maintained in contact with the end of the rack by a spring 339. Arm 338 is mechanically connected to and controls the position of the movable contact 341 of a single-pole double-throw switch 340. Rack 263 also controls a reversing switch 3-37 comprising a lever arm 342 that is mechanically linked to and controls the position of the movable contact 343 of the switch. Switch 337 is a toggle-action device, movable contact 343 changing its position only when lever 342 moves from one extreme position to another. The fixed contacts of switch 337 are connected to the field windings 332 and 333 of the actuator.

An essentially identical arrangement is used for hinge drill actuator 276 and comprises the spur gear 275 mounted on the actuator shaft in meshing engagement with rack 274. A pivotal lever 348 is maintained in engagement with one end of rack 274 by suitable biasing means such as a spring 49. Lever 348 controls the position of the movable contact 351 of a single-pole double-throw switch 350. A toggle switch 347, comprising a lever arm 352 controlling the operating position of a movable contact 353, is used at the other end of rack 274. The fixed contacts of switch 347 are connected to the two field windings of actuator 276.

There is one additional actuator 361 in the control circuit illustrated in FIG. 16 that does not perform a mechanical function in the machine but operates only as a control element for programming the sequence of operations carried out by the machine. Program actuator 361 comprises a small electrical motor having field windings 362 and 3&3 that are connected to each other, the common terminal of the windings being returned to system ground. A capacitor 364 is connected across the wind ings 362 and 363. The rotor 335 of the motor drives a program shaft 366 that actuates a series of single-pole switches 371 and 373-382 and a double-pole switch 372. Switches 371-382 may, for example, comprise individual cam actuated switches, the operating cams for the switches all being mounted upon the shaft 366 of actuator 361.

The control circuit of FIG. 16 is energized from an appropriate AC supply generally indicated by the input conductors 384 and 385. Conductor 384 is taken as the hot conductor and conductor 335 is shown as grounded. It should be understood, however, that an earth ground is not required and that an ungrounded system may be utilized if desired.

Conductor 384 is connected through a normally closed emergency stop switch 336 and through a manually operated switch 337 to one terminal of each of the drill and router motors. The other terminal of each of the motors is returned to system ground. Thus, by closing switch 387, the machine operator energizes all of the drills and routers and these devices are maintained in continuous operation while the machine is in use.

Power conductor 38 iis also connected through the emergency stop switch 385 and through the two sides of a normally open momentary-contact double-pole start switch 388 to the movable contacts 337 and 312 of actuators 227 and 124, respectively. Power conductor 384 is also connected to a buss 392 that is connected to the input terminal 393 for the program actuator 361. Moreover, a direct connection is taken from buss 384 to one terminal of each pole of the program control switch 372.

Program switch 371 is closed when program actuator 361 is in its initial or home position whereas the remaining switches 372-382 controlled by this actuator are held open in that position of the actuator. One terminal of switch 371 is connected to the *buss 332 and the other terminal of this switch is connected to the normally open contact of switch 338 of actuator 227. In the following description of the actuator switches, the expressions normally open and normally closed refer to the operating conditions of the switch Contacts when their actuators are in their respective home positions, as illustrated. The normally closed contact of actuator switch 308 is connected to one movable contact 394 of a double-pole double-throw reversing switch 395. For normal operation of the machine, contact 394 of switch 395 is connected to a fixed contact which is in turn electrically connected to winding 302 of actuator 227. Operation of the reversing switch 395 to its alternate position shifts contact 394 to engagement with a second fixed contact which is connected to the other winding 303 of actuator 227.

The reversing switch 395 includes a second movable contact 395. For normal operation, contact 396 engages a fixed contact connected to one winding of actuator 124 but upon actuation of switch 395 is moved to an alternate position in which it engages a fixed contact connected to the second winding of the actuator motor. Movable contact 396 is electrically connected to the normally closed contact of switch 313 of actuator 124. Contact 312, when moved to its alternate position, engages a normally open contact that is connected back through the program switch 373 to buss 392.

Program switch 372, as noted above, has one terminal of each pole connected directly to the power line 384. The other terminals of this switch are connected, respectively, to the two movable contacts 306 and 311 of switches 300 and 310 in actuators 227 and 124. The normally closed contact of switch 300 is connected to the buss 392. The normally open contact of switch 308 is connected to the movable contact 394 of reversing switch 395. The movable contact 311 of switch 310 in actuator 124, on the other hand, is maintained in engage'ment with a fixed contact that is open-circuited when the actuator 124 is in its home position. The normally open contact of switch 310 is electrically connected to the movable contact 396 of the reversing switch.

One terminal of each of program switches 374, 376, 377 and 379-382 is connected to a buss 398. Buss 398, in turn, is connected to the manual switch 387 utilized to actuate the drill and router motors and hence is continuously energized during operation of the machine. The other terminal of switch 374 is connected to the movable contact 315 of switch 318 in actuator 14-1. Similarly, the second terminal of switch 376 is connected to the movable contact 322 of switch 323 in router actuator 168. The normally closed contact in switch 318 is connected to the field windings of the actuator. The normally open contact of switch 318 is connected to conductor 392. A similar arrangement is used in actuator 158. That is, the normally closed contact of switch 323 is connected to the field windings of the actuator. The normally open contact of switch 323 is connected to conductor 392.

The normally closed fixed contact of switch 317 is electrically connected to the buss 392. The normally open contact of switch 317 is connected to the normally closed fixed contact of switch 318 and back to the field windings of the actuator. Similarly, the normally closed fixed contact of switch 328 in actuator 168 is connected to the buss 392 and this is also true of the normally closed contact of switch 327 in actuator 151. The normally open fixed contact of switch 320 is connected to the normally closed contact of switch 323, in actuator 168. The normally open contact of switch 327 in actuator 151 is connected to the normally closed fixed contact of switch 328 in the actuator and is also connected to the field windings of the actuator motor.

The movable contact 321 of switch 320 in actuator 168 is connected through program switch 377 to the buss 398. Similarly, the movable cam-actuated contact 325 of switch 327 in actuator 151 is connected through the program switch 379 to buss 398. The corresponding contact in actuatcr 141, contact 315, on the other hand, is connected through the program switch 375 to the normally closed fixed contact of switch 350 in cylinder drill actuator 276, the movable contact 351 of this switch being returned to buss 398. The switch connections for the three retarder actuators are completed by connecting the movable con tact 326 of switch 328 in actuator 151 in a circuit that extends to the program switch 378 and from that switch to the normally closed contact of switch 340, the movable contact 341 of the latter being connected back to conductor 398.

The connections for the strike drill actuator 206 are somewhat simpler than for the other positioning actuators. The movable contact 331 of the cam controlled switch 338 in this actuator is electrically connected to the field windings of the actuator motor. The normally closed fixed contact of this switch is connected through program switch 380 to buss 398. The normally open contact of the same switch is directly connected to buss 398.

The energizing circuits for the field windings 332 and 333 of bolt drill actuator 261 start with program control switch 381. Thus, switch 381 connects buss 398 to the movable contact 343 of the single-pole double-throw switch 337 in the energizing circuit of the actuator. A further connection is made from switch 381 to the normally open contact of the cam-actuated switch 340 in this actuator. A corresponding circuit arrangement is used for cylinder drill actuator 276, program switch 382 being connected to the movable contact 353 in the switch 347 that energizes the actuator windings and to the normally open fixed contact of the cam-actuated switch 350 controlled by the actuator.

In considering operation of the control circuit of FIG. 16, it should be understood that the switching devices of the control apparatus are in the illustrated positions at the start of a machine cycle. When the machine operator has loaded a door and a pair of jambs into the machine, he first closes switch 387 to energize the drill and router motors and to energize buss 398 if this has not already been done. The next step is to close start switch 388. Upon closing of this switch, lockset clamp actuator 227 is energized through a circuit beginning at buss 384 and extending through switches 386 and 388 to the normally closed contact of switch 308 and from switch 308 through switch 394 to the field winding 302 of the actuator. A similar operating circuit is established for the hinge clamp actuator 124, extending from switch 388 through switches 313 and 395 to the field winding of the actuator motor. Thus, the lockset clamp actuator 227 and the hinge clamp actuator 124 are both energized, and each drives its operating shaft through an angle of The rotational movement of shaft 228 of actuator 227 breaks the energizing circuit for the actuator after shaft 228 has rotated through one-half revolution, since cam 305 then engages the movable contact 307 of switch 308 and opens the operating circuit at this switch. Similarly, the operating circuit for hinge clamp actuator 124 is interrupted after one-half revolution of the actuator shaft by the opening of the normally closed contacts of switch 313.

During the initial portion of the operating cycle of the machine, the operator is requiredto hold start switch 388 closed to assure energization of each of the actuators 227 and 124 until they have each completed one-half revolution. This permits quick interruption of machine operation in the event that the operator observes that the jambs or the door are not being properly clamped in the machine. If there is an indication that clamping is not proceeding as required, and the operator interrupts the clamping operation by releasing the start switch 388 prior to completion of the operating cycles for actuators 227 and 184, the door and jamb members may be partially clamped in the machine. They are readily released by the operator by actuating reversing switch 395 to reverse the field connections to the actuator motors. This drives the actuators back to their initial positions and releases the lockset clamp and the hinge clamps to permit removal of the jambs and door from the machine.

Near the end of the operating cycle for actuator 227, cam 305 engages movable contact 307 to open the ener- 19 gizing circuit for the actuator, as described above. The cam further causes movable contact 307 to close on the upper or normally open contact of switch 308 and completes an operating circuit, through start switch 388, to the buss 392 that energizes the program actuator 361.

With actuator 361 energized, the actuator shaft 366 is driven and, after a short period of time, opens switch 371 in the energizing circuits to actuator 227 and to buss 392. Before switch 371 opens, however, switch 373 is closed by shaft 366 of actuator 361, completing an alternate energizing circuit for buss 392 and hence maintaining actuator 361 energized. This alternate energizing circuit goes from buss 392 through switch 373 and switch 313 and back through switches 388 and 386 to the AC. power line 384. This circuit, of course, can only be completed if hinge clamp actuator 124 has been energized and has been operated through a cycle of 180 to close contact 312 of switch 313 on the normally open contact of the switch. Thereafter, actuator 361 is held in operation until it opens switch 373 to break the energizing circuit for the actuator.

From the foregoing description, it will be apparent that at the beginning of the operating cycle the program actuator 361 can only be initially energized through switch 371. Furthermore, the circuit through switch 371 can only be completed if lockset clamp actuator 227 has completed its initial cycle of operation and has actuated switch 308. Furthermore, the initial cycle of movement of the program switches controlled by actuator 361 can be completed only if the energization of the control actuator is continued after switch 371 has opened as a result of completion of an alternate operating circuit through switch 373. This alternate or second energizing circuit for the program actuator 361 is dependent upon the completion of the hinge clamp operating cycle by actuator 124, since the circuit extends through switch 313 in that actuator. Accordingly, the initial stage of operation of control actuator 361 is dependent upon complete functioning of the lockset clamp mechanism controlled by actuator 227 and of the hinge clamp mechanism controlled by actuator 124. This prevents the initiation or completion of any drilling or routing operations unless and until the door and the jambs are fully and properly clamped in the machine.

Just before program switch 373 is opened to interrupt continuing operation of the program actuator 361, program switch 374 closes. Closing of this switch completes an operating circuit for the first router actuator 141, the circuit extending from buss 398 through switch 374 and through the normally closed contact of switch 318 to the field windings of the actuator motor. When thus energized, actuator 141 drives shaft 139 through one-half revolution, at which time the actuator cam 314 engages movable contact 316 and opens switch 318. During this cycle of operation of actuator 141, the three routers for forming the hinge receptacles in the door and in the hinge jamb are advanced into contact with the work and the routing operation is initiated as described above.

Upon completion of the half-revolution cycle of actuator 141, as described above, movable contact 316 of switch 318 is brought into engagement with the normally open fixed contact of the actuator. This completes an operating circuit for program actuator 361, the circuit extending from buss 392 through switch 318 and program switch 374 to buss 398. Accordingly, the program actuator 361 resumes operation and rotates control shaft 366 until program switch 37 4 is subsequently opened.

Just before program switch 374 opens, program switch 376 closes. This energizes router actuator 168 through a circuit beginning at buss 398 and extending through switch 376 and switch 323 to the actuator motor. Actuator 168 is driven through an operating cycle in which shaft 169 is rotated 180, moving the routers upwardly as described above. Moreover, the 180 rotation of shaft 169 rotates cam 319 and, at the end of the cycle, opens the energizing circuit for the actuator by disengaging movable contact 20 322 of switch 323 from the normally closed contact of the 'switch. Actuation of switch 323 also is effective to again complete an energizing circuit for program actuator 361, this circuit extending from buss 398 through switches 376 and 323 to the program actuator buss 392.

The resultant further energizationof program actuator 361 drives the program shaft 366 until program switch 376 is opened to interrupt the operating circuit. Before switch 376 opens, switch 378 closes to afford an energizing circuit for actuator 151. The energizing circuit for the router actuator 151, beginning at the router motor, extends through the normally closed contacts of switch 323 and through switch 378 to the normally closed contacts of switch 340 in the bolt drill actuator 261 and from switch 340 back to the buss 398. Actuator 151 is operated through a rotational cycle to drive the routers horizontally, as described above. At the end of one-half revolution of the actuator shaft 152, the cam 324 actuates switch 328 to interrupt the energizing circuit for the actuator and to complete an energizing circuit for program actuator 361 through the normally open contacts of switch 328, which are now closed.

With program actuator 361 again energized, the program shaft 366 is advanced until switch 378 opens. Just prior to the opening of program switch 378, switch 377 is closed to complete an operating circuit from buss 398 to the movable contact 321 of switch 320 in router actuator 168. Since the router actuator has been operated through a half-revolution cycle from the position shown in the drawing, movable contact 321 is closed upon the normally open contact of switch 320 with the result that an operating circuit is completed to the actuator motor. Accordingly, actuator 168 is again energized and rotates shaft 169 through an additional half-revolution cycle, back to its original position, driving the routers downwardly to their starting level. Upon completion of this cycle of actuator 168, switches 320 and 323 are returned to their initial operating conditions as illustrated, the energizing circuit for the actuator being broken at switch 320. The return of switch 320 to its original condition completes a new energizing circuit for program actuator 361, the circuit extending through program switch 377 (now closed) and switch 320.

With the program actuator again energized, program shaft 366 is rotated until switch 377 is opened, de-energizing the program actuator. Shortly before switch 377 opens, switch 379 is closed to energize the horizontal router actuator 151. The energizing circuit for actuator 151 extends from buss 398 through switch 379 to switch 327, the movable contact 325 of switch 327 now being closed upon its upper or normally open contact and hence completing a circuit to the actuator motor. Accordingly, actuator 151 is driven through an operating cycle of onehalf revolution returning to the position illustrated in the drawing. When this cycle is completed, the energizing circuit for actuator 151 is broken at switch 327 and a new energizing circuit for the program actuator 361 is established through this switch and through switch 379.

The program actuator 361 again advances control shaft 366, remaining in operation until program switch 379 is opened. Just before switch 379 opens, program switch 375 is closed to complete an operating circuit for the router actuator 141 that controls advancement and retraction of the routers. Thus, closing of switch 375 energizes actuator 141 through an operating circuit that extends from the actuator motor to the upper contact of switch 317, which is noW closed upon movable contact 315, and through switches 375 and 350 to the buss 398.

Router actuator 141 is driven through an operating cycle of 180, returning to the initial operating condition illustrated in FIG. 16. Upon completion of the halfrevolution cycle, the energizing circuit for the actuator is interrupted at switch 317 and a further energizing circuit is established for program actuator 361 through the contacts of switch 317 and through program switch 375.

With program actuator 361 energized through switch 375, program shaft 366 is again rotated until switch 375 is opened. Shortly before switch 375 opens, switch 372 closes. The closing of program switch 372 establishes operating circuits for each of the clamp actuators 227 and 124 through the switches 300 and 310, respectively, since both switches are in their alternate operating conditions with the movable switch contacts engaged with the upper normally open contacts. With the two clamp actuators energized, the clamp mechanisms are driven back to released condition as described above, releasing the doors and the jambs so that they may be removed from the machine by the operator. During this interval, the program actuator 361 is not energized; however, upon completion of the half-revolution cycle of either of the clamp actuators, the program actuator is again energized through switch 372 and through either one of switches 300 and 316.

Program actuator 361 remains energized and continues to rotate program shaft 366 until switch 372 is opened to interrupt the energizing cycle for the actuator. Shortly before this occurs, switch 371 is closed, restoring the program mechanism to its original condition. That is, when program switch 372 opens, the apparatus is back at its home position ready for the next machining operation.

Early in the operating cycle of the machine, at a time when program switch 373 is closed, program switch 3% closes by operation of program shaft 366. Closing of switch 380 establishes an operating circuit for the strike drill actuator 206, this circuit extending from buss 398 through switch 380 and through the normally closed con tacts of switch 33h to the actuator motor. Shortly after actuator 266 starts in operation, rotation of the actuator shaft releases movable contact 331 of switch 331), opening the original energizing circuit but completing an alternate energizing circuit for the actuator through the other fixed contact of switch 330, this alternate energiz' ing circuit being independent of program switch 330. Thereafter, actuator 2196 operates through an operating cycle in which the actuator shaft is rotated through a full revolution to first advance the drill 203 (FIG. 12) and drill the strike receptacle in the lock jamb of the door, and then to retract the drill to its original condition. When the shaft of actuator 2&6 has completed a full revolution of 360 it again actuates switch 331 to interrupt the operating circuit for the actuator. By this time, program switch 380 has again opened and the strike drill actuator 206 is not again energized until the next operation of the machine.

At about the same time that program switch 380 closes, that is to say while program switch 373 is closed, program switch 331 is also closed by operation of program shaft 36-6. The closing of switch 381 completes an energizing circuit 'for bolt drill actuator 261, this circuit extending from buss 398 through the reversing switch contact 343 to the one coil 333 of the actuator motor. Consequently, rotor 335 starts to rotate, driving spur gear 262 and moving rack 263 to the right from its initial position as shown in FIG. 16. The movement of rack 263 also begins advancement of the lock bolt drill 266 as described hereinabove (FIGS. 13 and 15).

With the initial movement of rack 263, switch 341) is actuated, through spring 339, disengaging movable contact 341 from the normally closed contact of the switch and engaging that contact with the normally open contact of the switch. Consequently, when program switch 331 subsequently opens, actuator 261 remains energized through the connection from buss 398 to movable contact 341 of switch 340 and from switch 340 to the reversing switch contact 343.

When rack 263 reaches the extreme right-hand limit of its travel, abutment 344 strikes lever 342 and actuates the reversing toggle switch 337 for actuator 261, displacing contact 343 from its initial position and closing this contact on the motor field terminal connected to coil 332. This reverses the direction of rotation of the actuator motor and begins to drive rack 263 back to the left, as seen in FIG. 16, toward its initial position. The reversal in direction of rotation of the actuator motor thus begins withdrawal of the drill shaft from the bolt aperture that has been drilled in the door. When rack 263 reaches the original position shown in the drawing, the energizing circuit for actuator 261 is interrupted at switch 340 since movable contact 341 returns to its original position. Reversing toggle switch contact 343 may simultaneously return to its original position, or this switch may function immediately at the beginning of the next succeeding cycle of operation of actuator 261.

Operation of cylinder drill actuator 276 is essentially similar to that described above for lock 'bolt drill actuator 261, but occurs later in the machine cycle. Thus, program switch 382 closes during the period of machine operation in which program switch 378 is closed. This energizes actuator 2'76 and brings the advancing movement of cylinder drill 277 to drill the cylinder aperture 55 in the door (FIG. 15), as spur gear 275 drives rack 274.

In response to the initial movement of rack 274, switch 35% (FIG. 16) is operated from its initial position as shown in the drawing to complete an alternate energizing circuit for actuator 276 that is dependent of control switch 382. When rack 274 reaches the end of its travel, toggle switch 3 37 is actuated, the direction of rotation of the actuator motor is reversed, and the drill is withdrawn from the door, the reversal of the actuator motor driving rack 274 back to its initial position. When the rack reaches the initial position as shown in FIG. 16, switch 351) is again actuated back to its original operating condition. As before toggle switch 347 may return to its original position simultaneously with operation of switch 359 or may be actuated immediately at the beginning of each cycle.

The two lockset drill actuators 261 and. 276 are interlocked with the router actuators 151 and 141, respectively, to prevent any possibility that the routing operations will be completed and the workpiece clamps released when the lockset drilling operations are not finished. Thus, during the time interval in which the lock bolt drill actuator 261 is energized, the initial operating circuit for router actuator 151, through program switch 378, cannot be completed because the circuit is open atv switch 34-0. Stated differently, the full cycle of operation for bolt drill actuator 261 must be completed and switch 341 must return to its original operating position before the hinge router actuator 151 can 'be energized to perform the initial horizontal movement of the routers. Furthermore, under these conditions it is not possible to complete the energizing circuit for program actuator 361 described hereinabove that must be stablished through switch 378 at one stage of the machine program. Accord ingly, it is seen that the machine program cannot be completed unless and until lock bolt drill actuator 261 performs the operations necessary to drill the bolt aperture in the door.

The same condition applies with respect to program switch 375 and the energizing circuit for actuator 141 that is employed to withdraw the routers from working position. Thus, when switch 375 closes, in the course of the machine program, it is efiective to energize router actuator 141 only if the cylinder drilling operation has been completed by actuator 276 and actuator 276 has returned to its initial operating position with switch 350 in the illustrated position. Again, continuing operation of actuator 361 and completion of the machine control program is dependent upon an energizing circuit that extends through switch 375 and through switch 350 of actuator 276 so that the program cannot be finished unless the cylinder aperture has been drilled into the door.

The interlocking circuits afforded by switches 340 and 3511 do not delay the completion of the routing opera- 23 tions and do not add to the total time required for the normal machine program. The normal timing of the machine is such that the drilling operations taking place at the lockset drill head 62 of the machine are completed before the time when the interlocked router actuators would ordinarily be energized. All that the interlock connections do is to assure completion of the complete machine program, including the lockset drilling operations, before the program actuator 361 completes its cycle and releases the workpieces from their clamped relation ship in the machine. The time required for the lockset drilling operations (and for the drilling of the striker plate receptacle) is substantially shorter than the time required for the routers to complete the hinge receptacles so that there is an ample time margin with respect to completion of the machine program and release of the clamps holding the door and the jambs in the machine.

From the foregoing description, it will be apparent that the automatic routing and drilling machine 60 of the present invention effectively forms the hinge plate receptacles, the lockset apertures, and the striker plate receptacle in a matching door and pair of door jambs in a single machine operation. The machine may be quickly and conveniently adjusted to accommodate a wide variety of standardized door widths, lengths, and thicknesses and may be adjusted with equal flexibility to provide for fabrication of left-hand or right-hand door assemblies. None of the components of the door assembly are moved during the drilling or routing operations. The door and jambs are easily and quickly loaded into processing position and there are no drills or routers located above the work to interfere with the machine operator. The ad justments required in the routing mechanism to accommodate the direction of hanging of the door are quite simple and are easily effected and the minor adjustment provided for changes in door height is also easily accomplished. The machine inherently provides precision alignment of the lock bolt receptacle in the door and of the striker plate receptacle in the lock jamb of the door assembly. Nevertheless, the machine is quite simple and inexpensive, though capable of a relatively high output,

Hence, while preferred embodiments of the invention have been described and illustrated, it is to be understood that they are capable of variation and modification.

I claim:

1. An automatic routing machine for single-operation routing and drilling of a door, a hinge jamb and a lock jamb, for hinges and a lockset, comprising:

means for supporting a door in a given plane;

means for supporting a hinge jamb in alignment with one longitudinal edge of said door but in a plane normal to the plane of said door;

means for supporting a lock jamb in parallel alignment and in the same plane with said hinge jamb;

a plurality of routers;

means for actuating said routers to rout said hinge jamb and said one longitudinal edge of said door in a single operation to afford a plurality of hinge receptacles therein;

a first drill for drilling the other longitudinal edge of said door to afford a lockset bolt receptacle therein;

a second drill for drilling said lock jamb to afford a strike receptacle therein;

fixed adjustable mounting means for mounting said drills with their axes located in a single fixed drill plane normal to the planes of said door and said jambs but permitting adjustment of said drills within said drill plane;

and stop means for locating said door and said jambs at either one of two different longitudinal positions to provide for routing and drilling of said door and said jambs for either right-hand or left-hand mounting without changing the location of said drill plane.

routing and drilling of a door, a hinge jamb and a lock jamb, for hinges and a lockset, comprising:

means for supporting a door with one side surface in a given horizontal plane;

means for supporting a hinge jamb in flush alignment with one longitudinal edge of said door and in a vertical plane above said door;

means for supporting a lock jamb in parallel fiush alignment and in the same plane with said hinge jamb and above said hinge jamb;

a plurality of routers mounted at one side of said vertical plane on a common support adjacent the conjunction of said hinge jamb and said one edge of said door;

means for actuating said routers to rout said hinge jamb and said one edge of said door in a single operation to afford a plurality of hinge receptacles therein;

a first drill for drilling the other longitudinal edge of said door to afford a lockset bolt receptacle therein;

a third drill for drilling the upper portion of said lock jamb from said one side of said vertical plane to afford a strike receptacle therein;

a second drill for drilling said door normal to the principal plane of the door to afford a cylinder receptacle intersecting said lockset bolt receptacle;

fixed adjustable mounting means for mounting all of said drills with their axes located in a single fixed vertical drill plane normal to the planes of said door and said jambs but permitting relative adjustment of said drills within said drill plane;

and stop means for locating said door and said jambs at either one of two different longitudinal positions to provide for routing and drilling of said door and said jambs for either right-hand or left-hand mounting without changing the location of said drill plane.

3. An automatic routing machine for single-operation routing and drilling of a door, a hinge jamb and a lock jamb, to receive hinges and a lockset, said machine being of substantially T-shaped configuration with the cross-bar of the T comprising a routing head and the leg of the T comprising a lockset drilling head, comprising:

means for clamping a door in said machine in a given plane, with one longitudinal edge of said door clamped against said routing head and with a medial portion of the opposite longitudinal edge clamped against said lockset drilling head;

means for clamping a hinge jamb and a lock jamb against said routing head in flush alignment with said one longitudinal edge of said door but in a plane normal to the plane of said door and with said lock jamb spaced from said door by said hinge jamb;

electrical actuating means for actuating the aforesaid clamping means between clamping and released positions;

a plurality of routers mounted within said routing head;

means for actuating said routers simultaneously to rout said hinge jamb and said one longitudinal edge of said door in a single operation to afford a plurality of hinge receptacles therein;

a first drill, mounted in said lockset drill head, for drilling the other longitudinal edge of said door to afford a lockset bolt receptacle therein;

a second drill, mounted in said routing head, for drilling said lock jamb to afford a strike receptacle therein, said drills being mounted with their axes parallel to each other and located in a common fixed plane normal to the planes of said door and said jambs;

and stop means for locating said door and said jambs at either one of two different longitudinal positions to provide for routing and drilling of said door and said jambs for either right-hand or left-hand mounting without changing the location of said drill plane.

4. An automatic routing machine for single-operation routing and drilling of a door assembly comprising, as components, a door, a hinge jamb and a lock jamb, said 2. An automatic routing machine for single-operation machine being of substantially T-shaped configuration with the cross-bar of the T comprising a routing head and the leg of the T comprising a lockset drilling head, comprising:

retaining means for retaining said door assembly components in said machine with one longitudinal edge of said door extending along said routing head and with said jambs in parallel flush alignment with said one edge of said door but normal thereto, said hinge jamb being interposed between said lock jamb and said door;

first clamping means for clamping said jambs and said door, at said routing head, both vertically and horizontally;

second clamping means for clamping the medial portion of the opposite longitudinal edge of said door, vertically and horizontally, at said lockset drilling head;

a plurality of routers mounted within said routing head;

means for actuating said routers simultaneously to rout said hinge jamb and said one longitudinal edge of said door in a single operation to afford a plurality of hinge receptacles therein;

first and second lockset drills, mounted in said lockset drill head, for drilling said door at its other longitudinal edge to afford intersecting lockset bolt and cylinder receptacles therein;

a third drill, mounted in said routing head, for drilling said lock jamb to afford a strike receptacle therein, said drills all being mounted in a fixed lockset drill plane normal to said jambs and aligned with the leg of said T;

and stop means for locating said door and said jambs at either one of two different longitudinal positions to provide for routing and drilling of said door and said jambs for either right-hand or left-hand mounting without changing the location of said drill plane.

5. An automatic routing machine for single-operation routing and drilling of a door assembly comprising, as components, a door, a hinge jamb and a lock jamb, said machine being of substantially T-shaped configuration with the cross-bar of the T comprising a routing head and the leg of the T comprising a lockset drilling head, comprising:

retaining means for retaining said door assembly components in said machine with one longitudinal edge of said door extending along said routing head and with said jambs in parallel flush alignment with said one edge of said door but normal thereto, said hinge jamb being interposed between said lock jamb and said door; first clamping means for clamping said jambs and said door, at said routing head, both vertically and in a direction parallel to the plane of said door; second clamping means for clamping the medial portion of the opposite longitudinal edge of said door, vertically and laterally, at said lockset drilling head; clamp actuating means for actuating the aforesaid first and second clamping means between clamping and released positions; a plurality of routers mounted within said routing head;

router actuating means for actuating said routers simultaneously to rout said hinge jamb and said one longitudinal edge of said door in a single operation over a given time interval to afford a plurality of hinge receptacles therein;

a first drill, mounted in said lockset drill head, for drilling the other longitudinal edge of said door to afford a lockset bolt receptacle therein;

a second drill, mounted in said routing head, for drilling said lock jamb to afford a strike receptacle therein, said first and second drills being mounted with their axes parallel to each other and to the plane of said door and located in a fixed lockset drill plane normal to said jambs;

a third drill mounted in said lockset drill head, with the axis of said third drill normal to the plane of said door but within said lockset drill plane, for drilling said door to afford a lockset cylinder therein;

drill actuating means for actuating said drills to drill said receptacles during said time interval in which said routers are actuated;

said clamp, router and drill actuating means each comprising an electrical motor having a mechanical connection to the device actuated;

and stop means for locating said door and said jambs at either one of two different longitudinal positions to provide for routing and drilling of said door and said jambs for either right-hand or left hand mounting without changing the location of said drill plane.

6. An automatic routing machine for single-operation routing and drilling of a door assembly comprising, as components, a door, a hinge jamb and a lock jamb, said machine being of substantially T-shaped configuration with the crossbar of the T comprising a routing head and the leg of the T comprising a lockset drilling head, comprising:

retaining means, including stop means for engaging the ends of said door assembly components to retain said door assembly components in two different longitudinal alignments, for left-hand and right-hand doors respectively, in said machine, with the door horizontal and one longitudinal edge of said floor extending along said routing head, and with said jambs in parallel flush alignment with said one edge of said door but vertically aligned, and with said hinge jamb interposed between said lock jamb and said door in both alignments,

said components being displaced longitudinally by a given distance D, in opposite directions, from a lockset drill plane parallel to the leg of the T and perpendicular to the door and the jambs;

first clamping means for clamping said j'ambs and said door at said rounting head, both vertically and horizontally;

second clamping means for clamping the medial portion of the opposite longitudinal edge of said door, vertically and horizontally, at said lockset drilling head;

a plurality of routers mounted within said routing head;

means for actuating said routers simultaneously to rout said hinge jamb and said one longitudinal edge of said door in a single operation to afford a plurality of hinge receptacles therein;

a first drill, mounted in said lockset drill head, for

drilling the other longitudinal edge of said door horizontally to afford a lockset bolt receptacle therein;

a second drill, mounted in said routing head, for drilling said lock jam horizontally to afford a strike receptacle therein; and

a third drill, mounting in said lockset drill head, for

drilling the door vertically to afford a. lockset cylinder receptacle therein communicating with said bolt receptacle, all of said drills having their axes located in said lockset drill plane.

7. An automatic routing machine for single-operation routing and drilling of a door assembly comprising, as

components, a door, a hinge jamb and a lock jamb, said machine being of substantially T-shaped configuration with the cross-bar of the T comprising a routing head and the leg of the T comprising a lockset drilling head, comprising:

retaining means for engaging the ends of said door assembly components to retain said door assembly components in two different alignments, for left-hand and right-hand doors respectively, in said machine, with the door horizontal and one longitudinal edge of said door extending along said routing head, and with said jambs in parallel flush alignment with said one edge of said door but vertically aligned, and with said hinge jamb interposed between said lock jamb and said door in both alignments,

Claims (1)

11. AN AUTOMATIC DRILLING MACHINE FOR DRILLING A DOOR TO RECEIVE A LOCKSET, COMPRISING: MEANS, COMPRISING A T-SHAPED FRAME FOR SUPPORTING A DOOR IN A GIVEN HORIZONTAL PLANE WITH ONE LONGITUDINAL EDGE OF SAID DOOR EXTENDING ALONG THE CROSS-BAR OF THE T AND THE OTHER LONGITUDINAL EDGE INTERSECTING THE LEG OF THE T; A FIRST CLAMPING DEVICE, MOUNTED ON THE LEG OF SAID FRAME ADJACENT SAID OTHER LONGITUDINAL EDGE OF SAID DOOR, FOR CLAMPING SAID DOOR AGAINST SAID FRAME TO PREVENT VERTICAL MOVEMENT OF SAID DOOR; A SECOND CLAMPING DEVICE, MECHANICALLY CONNECTED TO AND ACTUATED BY SAID FIRST CLAMPING DEVICE, FOR ENGAGING SAID OTHER LONGITUDINAL EDGE OF SAID DOOR AND CLAMPING SAID DOOR AGAINST THE CROSS-BAR OF THE T TO PREVENT HORIZONTAL MOVEMENT IN SAID PLANE NORMAL TO SAID CROSS-BAR; A DRILL CARRIAGE, MOUNTED ON THE LEG OF SAID FRAME FOR MOVEMENT TOWARD AND AWAY FROM SAID ONE EDGE OF SAID DOOR; A FIRST DRILL MOUNTED ON SAID DRILL CARRIAGE, FOR DRILLING SAID ONE EDGE OF SAID DOOR HORIZONTALLY TO FORM A LOCKSET BOLT RECEPTACLE THEREIN; CONNECTING MEANS FOR ADJUSTABLY CONNECTING SAID DRILL CARRIAGE TO SAID SECOND CLAMPING DEVICE TO LIMIT MOVEMENTS OF SAID DRILL CARRIAGE TO A PREDETERMINED RANGE AND THEREBY ADJUST THE BACKSET OF SAID BOLT RECEPTACLE; AND A SECOND DRILL, MOUNTED ON SAID DRILL CARRIAGE AND CONNECTED TO SAID CONNECTING MEANS, FOR DRILLING A TRANSVERSE LOCKSET CYLINDER RECEPTACLE, COMMUNICATING WITH SAID BOLT RECEPTACLE, IN SAID DOOR.

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