US3641645A

US3641645A - Apparatus for producing wall panels

Info

Publication number: US3641645A
Application number: US5792A
Authority: US
Inventors: George E Kunkle
Original assignee: Individual
Current assignee: Individual
Priority date: 1970-01-26
Filing date: 1970-01-26
Publication date: 1972-02-15
Anticipated expiration: 1989-02-15

Abstract

An apparatus for automatically forming wall panels by lacing or inserting studs having male dovetailed key members formed on the ends thereof into two plates having dovetailed keyways formed therein. The apparatus includes a supply bunk or rack for holding a plurality of studs to be laced, a stud clamp for grasping a stud from the box and positioning it for insertion into the keyways of the two plates, means for simultaneously pressing the stud into the keyways of the two plates, and mechanism for advancing the two plates and positioning the next consecutive keyways at a predetermined location for insertion of a next stud. The method includes the novel procedure by which the next consecutive keyways in the plates are positioned to receive a stud.

Description

United States Patent Kunkle, Jr.

[4 Feb. 15,1972

[54] APPARATUS FOR PRODUCING WALL PANELS [72] Inventor: George E. Kunkle, Jr., 2507 Cumberland Drive, Mesquite, Tex. 75149 [22] Filed: Jan. 26, 1970 [21] Appl.No.: 5,792

[56] References Cited UNITED STATES PATENTS 3,399,445 9/1968 Carroll ..29/200A Primary Examiner-Thomas H. Eager Att0rneyRichards, Harris & Hubbard [57] 1 ABSTRACT An apparatus for automatically forming wall panels by lacing or inserting studs having male dovetailed key members formed on the ends thereof into two plates having dovetailed keyways formed therein. The apparatus includes a supply bunk or rack for holding a plurality of studs to be laced, a stud clamp for grasping a stud from the box and positioning it for insertion into the keyways of the two plates, means for simultaneously pressing the stud into the keyways of the two plates, and mechanism for advancing the two plates and positioning the next consecutive keyways at a predetermined location for insertion of a next stud. The method includes the novel procedure by which the next consecutive keyways in the plates are positioned to receive a stud.

10 Claims, 10 Drawing Figures V PATENTEDFEB 15 1912 SHEET 1 OF 5 IN VENTOR GEORGE E. KUNKLE,JR

ATTORNEYS EATENTEDFEB 15 1912 3. 641 .645

sum u 0F 5 INVENTOR GEORGE E. KUNKLE, JR.

AT TORN E YS mwmrzms I912 3.s41,s45

SHEET 5 [1F 5 I46 INVENTOR:

GEORGE E. KUNKLELJR.

ATTORNEYS APPARATUS FOR PRODUCING WALL PANELS BACKGROUND OF THE INVENTION This invention relates to a machine for automatically assembling wall panels, each comprising two longitudinal end plates and a plurality of transverse studs connecting the end plates through dovetailed joints, and more particularly, relates to the mechanism for and control of the positioning of the plates and studs for mating the elements forming the dovetailed joints.

In accordance with U.S. Pat. No. 3,082,492 transverse dovetailed keyways are formed in header plates and baseplates for wall panels by providing for a thickness-compensated cut at the mouth of the dovetailed keyway so that a variation in plate thickness can be accommodated. Also in the past, a panel-assembling machine has been used in which plates are slid through an assembly station, periodically stopped in their travel, and studs having dovetailed male ends formed thereon inserted while the plates are stopped.

One of the problems with the prior assembly machine is that the positioning of the dovetailed ways at the assembly station is time consuming while requiring a certain amount of precision. If the dovetailed keyways in each of the two plates into which a stud will be inserted are out of alignment, a stud cannot be simultaneously inserted in the keyways of each of the plates without harming the resultant structure. Of course, if the keyways are too far out of alignment, mating the dovetailed end of the stud with the keyway in a given plate is virtually impossible, unless the stud ends are inserted individually into each of the respective keyways. If the latter were to be done, operation time would be almost doubled.

SUMMARY OF THE INVENTION The present invention therefore is particularly directed to improvements in a machine for automatically assembling wall panels wherein the handling of the plates and studs is automatic while assuring accurate positioning of the plates to receive the studs. The present invention therefore provides both a method and apparatus for automatically assembling wall panels formed from plates spaced apart by studs which are joined to the plates by dovetailed joints. The apparatus of this invention comprises two frame members mounted in a guideway on a base member, which frame members are mounted for movement toward and away from each other, means for advancing two of the plates and positioning the dovetailed keyways to receive a stud, the means for advancing being responsive to the insertion of a stud in preceding ones of the keyways in the plates, means operative upon positioning the keyways to receive a stud for inserting a stud into the keyways, meansfor supplying a plurality of studs to the means for inserting.

More specifically, the apparatus comprises two frame members mounted in spaced-apart relation on a base member, a plate guide mounted on each of said frame members, each substantially parallel to the other, each of the plate guides capable of receiving a plate having a plurality of dovetailed keyways formed therein, means for advancing the plates along the guides and including means for aligning consecutive dovetailed ways such that the ways are capable of simultaneously receiving a stud having a male dovetail portion at each endthereof, a stud clamp mounted for movement through a portion of a cylindrical path whose axis is parallel to the longitudinal dimension of the studs, the stud clamp mounted to grasp a preselected stud from a stack of studs and remove the stud from the stack through the path to a temporary support, a press means operative upon the arrival of the stud at the temporary support means for forcing the male dovetailed portion into the dovetailed ways.

The apparatus of the present invention for forming wall panels from plates having dovetailed ways therein, and from studs having male dovetailed ends thereon, wherein two of the plates are translated along a substantially parallel spacedupurt path by a drive means including drive members engaging the two plates, the drive members being driven by a common shaft, the shaft being driven by a drive means having brake and clutch mechanisms on the output side thereof comprises the means for advancing the two plates along substantially parallel paths, sensing the arrival of a first key at a predetermined location along the path of one of the plates and disengaging the clutch mechanism responsive to the arrival, sensing the arrival of a second key at a predetermined location along the path of the other of the plates and activating the brake after the arrival of the second key. The apparatus can additionally comprise positioning a stud in relation to the keys such that a unidirectional force will insert the end of the stud in the keys and inserting the stud into the keys responsive to the arrival of the second key at the predetermined location.

BRIEF DESCRIPTION OF THE DRAWINGS For a more complete understanding of the present invention and additional provisions and advantages thereof, refer to the ensuing specification and accompanying drawings where:

FIG. 1 is a diagrammatic view of the assembly of a wall panel by the apparatus of the present invention;

FIG. 2 is an enlarged view of the dovetailed joints which can be utilized with the present invention;

Flg. 3 is a front elevation view of the lacer apparatus embodying the instant invention;

FIG. 4 is a cross-sectional view taken along section line A- A of FIG. 3;

FIG. 5 is a cross-sectional view of the lacer apparatus taken along section line B-B of FIG. 3;

FIG. 6 is a cross-sectional view of the lacer apparatus of the present invention taken along section line C-C of FIG. 3;

FIG. 7 is a side elevation view of the stud clamp without its cover portion;

FIG. 8 is a top view of the stud clamp of FIG. 7;

FIG, 9 is a diagrammatic view of the apparatus for positioning keyways for receiving a stud;

FIG. 10 is a schematic circuit diagram of a portion of the total circuitry which operates the apparatus for positioning the keyways for receiving a stud.

DESCRIPTION OF A PREFERRED EMBODIMENT Referring now to the accompanying drawings, like numerals will be used where applicable to increase the clarity and understanding of the following description. For purposes of this description, a wall panel will be understood to include a pair of substantially parallel plates 10 and 12 (FIG. 1) with studs l4joined thereto at spaced intervals. In normal practice studs are placed at equally spaced intervals such as 16-inch of 24inch centers so that the wall panel when completed can be employed with like wall panels for forming the walls of a framed structure. If desired to vertically reinforce a portion of a wall panel which will be supporting a second story wall, for example, studs can be placed by the present invention at less than l6-inch centers. In accordance with the disclosure of U.S. Pat. No. 3,082,492 and 3,367,376, the description of the present invention will include wall panels constructed through utilization of dovetailed joints. Particularly, the ends of each of the studs 14 have a male dovetailed key 16 which mates with a female dovetailed keyway 18 formed in each of two

plates

10 and 12. Although utilization of the dovetailed joint is preferred, thepresent invention can be employed with a female keyway of any desired shape; including a dado cut into which an uncut end of a stud can be inserted.

In the enlarged view of FIG. 2, to which reference will now be made, it will be noted thereto the plate 12 has a stud 14 joined thereto through the use of the dovetailed connection involving the key 18 and the male key portion 16. In accordance with U.S. Pat. No. 3,082,492, the female way is formed with a special cut involving the surfaces 18a and "lb which permit the present invention to be utilized even though the thickness of the plates 10 and I2 may vary. The

surfaces

18a and 18b of plated 12 are milled at the same time the dovetailed keyway is milled so that the distance between

surfaces

18a and 18b and the surface 12a of the plate will be equal for all plates utilized with the present invention despite thickness variations in an actual plate. It follows then that the length of the stud 14 can remain constant and does not have to be adjusted to variations in keyway depth.

As illustrated in FIG. 1, plates and 12 are mounted such that they are spaced the proper distance apart and are moved intermittently in the direction of arrows 20. The apparatus for mounting the plates and forwarding them will be described hereinafter. At intervals when the dovetailed ways 18 are positioned at an assembly station, the bottom stud from the front row of a stack or bunk of 24 studs is grasped and transplanted along an arcuate path 22 to a rest position immediately above and with the keyed ends 16 thereof in alignment with the dovetailed ways 18. A lumber press then engages the ends 16 of the stud 14 to simultaneously force ends 16 into the ways 18. When this operation is completed, an automatic nailer is actuated to sink a nail or staple through the

plates

10 and 12 into each end 16 of the stud 14. Since the dovetailed ways are normally press fitted, the assembly will remain intact without additional connectors, however, one nail in each end is provided to assure that there is no movement of the dovetailed joint.

The apparatus of the present invention is designed and operated to assure positive alignment of the keyways 18 at the assembly station even though there may be a difference in the drive speeds or movement of plate 10 relative to plate 12'as they are translated to bring the next successive sets of dovetailed ways 18 to the assembly station. The control of movement of the

plates

10 and 12 is of course important in order to achieve an exact alignment between the ends 16 of the studs 14 and the keyways 18 before the lumber press engages the studs to force them into the keyways. As will be described more specifically hereafter, sprocket drives engage the top and bottom surfaces of

plates

10 and 12. These sprockets are actuated and rotated by way ofa common drive shaft. The shaft is powered from a drive means, for example, an electric motor, by way of a clutch on the output shaft of the drive means. The clutch is provided with a brake on its output shaft to stop the forward momentum of the drive system and the plates.

In accordance with this invention, the arrival of keyways 18 are separately sensed for each of the ways in

plates

10 and 12. The nondiscriminate arrival of a first of the two ways at its assembly station serves to disconnect the motor by releasing or disengaging the clutch, thereby allowing the first of the two keyways to promptly stop at the proper alignment point. Since there is inertia in the system and because of that fact, the clutch output shaft will continue to travel causing the trailing or second keyway to continue its movement until it is in proper alignment with the assembly station. When the second keyway comes into alignment, a sensor at the second assembly station serves to energize and apply the brake on the output shaft of the clutch, thereby immediately stopping the entire drive mechanism and thus the plate containing the second keyway.

The foregoing brief description will be further understood along with additional novel features of construction of the present invention by reference to the remainder of the drawings, FIG. 3 through 10.

Referring first to FIGS. 3 and 4, which is a front view of the lacer forming and embodying the present invention, the apparatus is provided with a

baseplate having supports

31 and 32 attached to the ends thereof. Channel 33 is secured to both

supports

31 and 32. An additional pair of supports 34 are provided at the rear of the unit supported by and connected to the base 30. The channel 33 has a rectangular bar 36 longitudinally mounted on the channel midway between the inner surface of the web thereof. Similarly, a channel 37 mounted on supports 34 has a rectangular bar 38 attached to its inner surface. A carriage is mounted for travel along

bars

36 and 38 by means of guide wheels 39 rotatably mounted thereon which cooperate with bar 36, and guide wheels 41 rotatably mounted on carriage 40 which cooperate with bar 38. As best seen in FIG. 3, the carriage 40 is relatively narrow with two of the wheels 39 riding on top of the bar 36 and one of the wheels 39 contacting the bottom of the bar 36. Similarly, the wheels 41 are so mounted. By this means, the carriage 40 can move longitudinally along the length of the lacer. In a similar manner a second carriage 50 is mounted on the left side of the lacer and is supported in identical fashion for movement toward and away from carriage 40. Carriage 40 is provided with an elongated rack 42 while carriage 50 is provided with an elongated rack 52. The racks pass through a control structure 53 mounted on the base 30 at the front center of the lacer. A pinion (not shown) mounted in the control unit 53 is provided to be actuated by way of crank 54 to move the carriages 40 and 50 toward and away from each other as desired. As will be seen later, this relative longitudinal opposite motion of carriages 40 and 50 is provided so that the lacer can accommodate studs of different lengths, thereby making it possible for the lacer of the present invention to produce wall panels of different heights.

The lacer apparatus is further provided with a pair of

end members

45 and 55. Three common shafts extending the full length of the lacer are rotatably mounted in bushings which are in turn attached to the

respective end members

45 and 55. The lower shaft 60 is the main powered shaft for actuation of the plate advance mechanism of the lacer. ldler shaft 61 is provided for mounting a pair of stud clamps and for mounting the top portion of the plate drive mechanism. A shaft 62 is provided for control of the position of the bunk or stack of studs in the apparatus.

Normally a bunk of studs is loaded into the lacer to rest upon a rack or bunk formed by rail 62 attached to carriage 40, a similar rail attached to carriage 50, a sideplate 64, and a similar sideplate on carriage 50. The end plate 64 is pivoted along its bottom margin so that when a bunk of studs is placed in the rack, the end plate 64 can be pivoted outward, with the top edge 58 of the end plate being moved away from the ends of the studs, i.e., downward from the plane of the paper as viewed in FIG. 4. The bottom edge remains fixed so that there will be a larger opening into which the bunk of studs can be lowered. After the studs are brought to rest on the rail 63, the end plates are rotated back to a vertical position to substantially contact the confronting ends of the studs. The back surface ofthe bunk ofstuds is then engaged by a pusher frame 65. The frame 64 is mounted for sliding movement on the rail 63 and is driven forward and backward by a chain (not shown) mounted on an idler sprocket and shaft 66 and a driven sprocket and shaft 62. As seen in FIG. 3, the shaft 62 is driven at the right-hand end by a motor 67 through a chain drive mechanism 68 and at the left-hand end by a motor 69 through a chain drive mechanism 70. Thus, the shaft 62 is driven at both ends. When it is desired to move a bunk of studs in the direction of arrow 71,

motors

67 and 69 are simultaneously energized to move the bunk of studs until the front stack of studs in the bunk engages the face 72 ofthe front stop.

At this point, the front row of studs overlays the stud sensor 73, which is biased upwardly by a spring 74. The front row of studs causes the sensor which is mounted for sliding vertical movement to be lowered to a depth corresponding to the thickness of one stud so that the one stud on the front row of the bunk is one thickness below the plane of the remaining stacks of studs in the bunk as they rest upon rail 63. In this position a stud pickup arm is actuated to grasp the bottom stud and move it along an arcuate path so that the ends thereof are positioned directly above a keyway in a plate at the assembly station. To insure that the front stack of studs, and especially the bottom stud in that stack is the width of one stud below the rest of the stacks of studs, a hydraulic arm 75 is provided which engages the top stud in the front stack of studs through the hydraulic cylinder mechanism 76 so that the front stack of studs will always be pressed firmly down on the sensor surface 73. When the last stud in a given front stack has been removed by the pickup arm, the cylinder 76 is actuated to elevate the stud arm. Thereafter the

motors

67 and 69 are actuated to move the bunk of studs forward one stud width so that the next column rests on the sensors 73. It should be noted here that although the mechanism is being primarily described with relation to the right-hand carriage and the mechanisms thereon, it is to be understood that the left-hand carriage has mechanisms corresponding to and performing substantially the same functions as those on the right-hand carriage 40. The left-hand carriage 50 and mechanisms thereon are in essence a mirror image of the right carriage assembly.

Before discussing the construction and operation of the pickup arm, it should be noted that the plates with keyways therein are mounted on a bed 77 and are guided by a vertically rotatable roller 78 mounted on the bed 77. Similarly, a like set of rollers is provided on the frame forming part of the carriage 50.

The plates and 12 (shown only in FIG. 3) are driven by a pair of sprockets which engage the top and bottom portions of the plate. The lower sprocket 80 is mounted with the teeth thereon just protruding above the surface of the bed 77. Referring to FIG. 5, sprocket 80 is driven through shaft 81, which is in turn driven through chain mechanism 82 by shaft 60. The shaft 81 is mounted for rotating motion through the carriage 40 and thus sprocket 81 is fixed in its position with the teeth thereof capable of embedding themselves in the bottom surface of a plate placed on bed 77. The upper sprocket 83 is mounted on a movable arm 84 and is driven through a chain and sprocket arrangement mounted on idler shaft 61. Arm 84 also pivots about idler shaft 61 to raise and lower sprocket 83. Thus, sprocket 83 can be disengaged from the top portion ofa plate to remove a completed wall panel and to insert a new plate for the formation of a wall panel. Sprocket 83 is driven by the chain and sprocket mechanism (not shown) within arm 84 which is in turn driven from shaft 81 through chain and sprocket arrangement 85. The movement of arm 84 is actuated by hydraulic cylinder 86 through rod 87 which is pivotally attached to arm 84. Cylinder 86 is attached at its oppositeend to carriage 40. Thus, the sprockets 80 and 81 are intermittently powered to drive the plate 10 in the direction or arrow 20 as shown in FIG. 1. 1

The pickup arm, generally designated 90, ,is an assembly which is mounted for pivotal movement on idler shaft 61. The idler shaft 61, at a point near where the pickup arm is rotated, is supported by brace 91 attached to carriage 40. The pickup arm is controlled as to'position by hydraulic cylinder 93 which has its piston rod pivotally attached to the pickup arm at 8 9. Cylinder 93 is pivotally attached at its other end to rail 63 through support member 94. For purposes of clarity, the piston 93 is not shown in FIG. 3 but appears in FIG. 4. The pickup arm is illustrated in its extended or horizontal position. When the piston of cylinder 93 is retracted, the pickup arm rotates along an are so that it is in a vertical position.

For a better understanding of the pickup arm and its operation, reference should be made to FIGS. 7 and 8 wherein the pickup arm is shown in its horizontal or extended position and wherein the protective cover portion of the pickup arm appearing in FIG. 4 has been deleted so that the inner mechanism of the pickup arm is apparent. With reference now to FIGS. 4, 7 and 8, when the pickup arm is in its vertical position, a clamp dog 95 cooperates with a fixed jaw 101 to grasp the bottom stud in the front stack resting on sensor 73. A push dog 96 shown in an extended position is retracted when the pickup arm is in its vertical position, such that its front surface 97 can engage the rear portion of a stud being held by the clamp dog 95. When the pickup arm is being raised to the vertical position, the clamp dog 95 is rotated back out of line of the jaw surface 98 so that the fixed jaw 101 will engage the front side of the bottom stud. In this position the clamp dog 95 is actuated so that the tooth thereof impales the back side of the stud. '

Microswitches

108 and 110 are provided to assure proper operation of the pickup arm 90. Switch 108 is activated by sensor 73 in its lowered position. Switch 110 is activated by the pickup arm in its vertical position. Both switches must be activated before the pickup arm will return to its horizontal position with a stud it has grasped from the bottom of the stack resting on sensor 73. Thus, if switch 108 is not activated, it is an indication of the absence of studs on sensor 73, requiring the placement of a new stack from the bunk of studs. If switch 110 is not activated, it is an indication that the pickup arm has for some reason malfunctioned by not properly returning to the upright position or by not correctly grasping a new stud from the stack.

From the vertical position, the cylinder 93 is actuated to return the pickup arm to its horizontal position. At this movement is initiated, the bottom stud in the front stack is removed from under the bottom of the stack and rotates along an arc to a horizontal position. The clamp dog is actuated by hydraulic cylinder arrangement 99 and the push dog 96 is actuated by hydraulic cylinder arrangement 102. A microswitch 103 is actuated which serves to release the clamp dog 88 and to actuate the push dog 96. The push dog 96 slides the stud forward off the fixed jaw 101 and onto a weigthbiased temporary support arm 104. As shown in FIG. 4, the temporary support arm is pivoted at 105, the right hand portion thereof being sufficiently weighted so that the weight of the stud (shown only in FIG. 4) resting thereon will not cause the support 104 to pivot. In this position, the front face of the studis in contact with the surface of lumber stop 106. In this position, the stud is poised with the shaped end thereof in alignment with the dovetailed way which has been previously positioned at the assembly station. After the stud has been inserted into the two plates, the pickup arm 90 is returned to a vertical position, ready to grasp the next stud at the bottom of the front stack of studs resting on sensor 73.

A hydraulic press 120, powered by a hydraulic cylinder (not shown) within carriage 40, serves to press the stud from its position as shown in FIG. 4, into the previously positioned keyways of the plates. As the hydraulic press engages the stud 100 to push it downward into the keyways, the temporary support 104 pivots out of the way to allow downward movement of the stud.l00. After the stud has passed the temporary support 104, the support trips back into the position as shown due to the weight-biased right-hand end thereof.

A curved arm 121 pivoted at 122 extends into the path of a stud as it moves down to the bottom of its course during insertion into the keyways. As the arm 121 is moved downward, it actuates a microswitch 123 to energize a nailing or stapling gun (not shown) housed within carriage 40 to inject a nail from the outer surface of the plate into the end of the stud. Thus, the system automatically assembles keyed studs with suitably formed plates to provide wall panels ready for use in the construction trades.

Referring now to FIG. 6, in one aspect of the invention, the shaft 60 is driven by way of a chain engaging sprocket 131, which is keyed to shaft 60. Shaft 60 is coupled by suitable drive mechanism, as hereinbefore described, to both of sprockets 80 and 81. A motor 132 drives a clutch 133 and thence through a gear train to a sprocket 134, which in turn drives the chain 130. Interposed between the clutch 133 and the sprocket drive 134, is a brake mechanism for stopping the rotation of sprocket 134, and, hence, shaft 60. The brake and clutch mechanisms are of the conventional electrically powered, magnetic type. The control of the drive mechanism is thus common to both

plates

10 and 12, since the left-hand plate is driven by sprockets which in turn are driven through the common shaft 60. However, since the plates utilized in the present invention can be of different materials permitting the drive sprockets to imbed themselves more deeply in one plate than in the other, for example, the velocity at which one plate travels can differ from the velocity at which the other plate travels. Even though the dovetailed keyways are equally spaced on the two studs, one such keyway may be positioned in alignment with the assembly station before the other.

Referring now to FIG. 9, the apparatus and method by which it is assured that both keyways are properly aligned at the assembly station will be described. A pin mechanism generally shown on FIG. 4 as 140, is positioned at the dovetailed joint assembly station. Referring to FIG. 9, a diagrammatic view of the mechanism for stopping the advance of

plates

10 and 12 in the direction of the arrows is illustrated. A pin arrangement, generally designated 140, for the righthand side of the lacer apparatus is connected to the carriage 40 by means not here shown. A similar pin arrangement, generally designated 160, is attached to carriage 50, also by means not shown. The

pin arrangements

140 and 160 locate the position of the assembly station for the wall panels. The pin arrangement 140 includes a bushing 141 and a spring 142, which biases the pin 143 in an upward direction by contact with retension rod 148. The pin 143 extends through an appropriate hole 149 in the surface of the guide 77. The pin 143 is thus mounted for sliding, reciprocal motion in the direction of arrow 144. The bottom of pin 143 engages an arm 145 ofa microswitch 146.

As can readily be seen, when a stud is pressed into the dovetailed keyway 18, the pin will be depressed such that the plate 10 can be moved forward in the direction of arrows 20. As the next consecutive keyway is positioned over the pin 143, it will rise into the keyway, serving a dual purpose. The first purpose is to provide a rest or positive stop against which the surface 147 of the keyway 18 can engage, thus, determining the point at which the plate 10 will cause its motion in the direction of arrows 20. Second, since the pin 143 is contacting the switch arm 145 of the microswitch 146, the microswitch will be activated. The operation of the pin arrangement 160 is similar to that of pin arrangement 140, with the pin 163 rising into the keyway 18 of plate 12 as it arrives at the pin location. Similarly, microswitch 166 is activated by the upward movement of the pin. As will be described hereinafter,

microswitches

146 and 166 are connected by appropriate circuitry to the clutch 133 and the brake described in conjunction with FIG. 6. To reiterate, the clutch and brake mechanism are the primary drive source for shaft 60 which in turn drives the

sprockets engaging plates

10 and 12 to translate them in the direction of arrows 20. The clutch 133 is so connected to the

microswitches

146 and 166 that it will be disengaged upon either of

pins

143 and 163 first rising into respective keyways, thus cutting off the power to the drive mechanism for translating the

plates

10 and 12. As the second keyway comes into position such that its respective pin rises thereinto, the

microswitches

146 and 166 are so connected to the brake mechanism on the output shaft of clutch 133 that the brake will be engaged. The inertia of the drive system will provide sufficient translational energy to move the lagging keyway into its proper position for assembly after the clutch is disengaged. However, to prevent harm to the keyways and to the

pin mechanisms

140 and 160, the brake is provided to stop the entire drive mechanism. Thus the

pin arrangement

140 and 160 provide the mechanism whereby the plates are automatically positioned so that the next respective stud can be positioned in the keyways 18 of the

plates

10 and 12, without fear of misalignment or damage to the plates.

Referring now to FIG. 10, the circuitry associated with

switches

146 and 166 for engaging and disengaging the clutch and brake mechanisms in the drive train for

plates

10 and 12 is schematically illustrated. The

switches

146 and 166 can be of the double-pole, double-throw type. The switches are connected in series to a suitable source of alternating current 170. The poles 171 of switch 166 are electrically connected and in turn are connected to the alternating current source 170. Contact 172 of switch 166 is electrically connected to pole 174 of switch 146. Contact 173 of switch 166 is electrically connected to pole 175 of switch 146. A relay coil 177 is connected in series between contact 176 of switch 146 and the alternating current source 170. The relay coil 177 corresponds to the brake mechanism on the output shaft of the clutch hereinbefore described. As coil 177 is energized, the brake mechanism will be activated to stop the drive train for shaft 60 (FIG. 6). A second relay coil 179 is connected in series between contact 178 of switch 146 and the alternating current source 170. The relay coil 179 when energized will in turn engage the clutch 133 between the motor 132 and the shaft 60 (FIG. 6).

The sensing pins 143 and 163 described in conjunction with FIG. 9 are shown connected to the two switch arms of each of

switches

146 and 166, respectively. For example, when both

switches

146 and 166 are in a lowered position B and B indicating that a keyway is not at the assembly station, a circuit is made through poles 171, contact 173, pole and contact 146 to energize the clutch relay coil 179, thus causing the

plates

10 and 12 to move in the direction of arrows 20 (FIG. 9). When one of the keyways 18 arrives at the assembly station its respective pin, for example pin 143, will shift from position B to A thus breaking the circuit at contact 178. This in turn deenergizes the clutch relay coil 79 to disengage the clutch mechanism. At the same time a circuit is completed between pole 174 and contact 176 of switch 146. When the second keyway arrives at the assembly station the respective pin, for example pin 163, will rise into the keyway. As the second pin so rises, a circuit will be made between pole 171 and contact 172 of switch 166, thus completing the circuit to brake relay coil 177. As this circuit is completed the brake mechanism for the drive train of shaft 60 is engaged to stop movement of the drive train for the

plates

10 and 12. Similarly as a stud is inserted in the keyways 18 of

plates

10 and 12, pins 143 and 163 will again cause a circuit to be made through the clutch relay coil 179. The

plates

10 and 12 will then be forwarded in the direction of arrows 20 until the next consecutive keyways arrive at the assembly station. A switch 180 is provided to manually deactivate the brake and clutch coils regardless of the position of

pins

143 and 163. In addition, provision can be made to prevent the clutch relay coil from engaging the clutch until the lumber press 120 (FIG. 4) has moved a sufficient distance above the plates after inserting a stud in the keyways.

Although the foregoing invention has been described in relation to a preferred embodiment it is apparent to one of ordinary skill in the art that various and diverse modifications can be made without departing from the invention herein described which is particularly defined in the appended claims.

What is claimed is:

1. An apparatus for production of wall panels formed from plates spaced apart by studs connected through joints including a female keyway comprising:

two frame members mounted in spaced-apart relation on a base member;

a plate guide mounted on each of said frame members, each substantially parallel to the other and each capable of receiving a plate having a plurality of dovetailed keyways formed therein,

means for advancing said plates along said guides and including means for aligning consecutive keyways such that said keyways are capable of simultaneously receiving the ends of a stud,

a stud clamp mounted for movement through a portion of an arcuate path whose axis of generation is parallel to the longitudinal dimension of the stud, said stud clamp mounted to grasp a preselected stud from a stack of studs and move the stud from the stack through said path to a temporary support,

and a press means operative upon the arrival of said stud at said temporary support means for forcing said ends of said studs into said keyways.

2. The apparatus of claim 1 wherein the said frame members are mounted on said base members for movement toward and away from each other, thereby said apparatus is capable of receiving and operating upon studs of various lengths.

3. The apparatus of claim 2 wherein said advancing means comprises at least two sprockets mounted for rotation on each of said frame members, one of said sprockets mounted to engage the bottom of a plate in said plate guide, one of said sprockets mounted to engage the top of a plate in said plate guide, at least one of said sprockets on each frame member driven through a common shaft mounted for sliding and rotating motion in each of said frame members, and means for driving said common shaft.

4. The apparatus of claim 1 wherein said stud clamp is mounted for movement through a cylindrical path on an idler shaft, and said idler shaft is mounted for rotating and sliding motion in each of said frame members.

5. The apparatus of claim 4 wherein a stud clamp is mounted near each of said frame members on said idler shaft, and drive means for moving each of said stud clamps through a cylindrical path.

6. The apparatus of claim 5 wherein each of said stud clamps comprises an arm mounted for rotation on said idler shaft, a projection attached to said arm, a digital clamp means mounted for movement on said arm for grasping a stud between said clamp means and said projections, and pusher means for removing a stud from said stud clamp and onto said temporary support.

7. The apparatus of claim 6 further comprising a rail mounted on each of said frame members capable of supporting a plurality of studs, and means for feeding said studs to a predetermined position whereat one stud of said plurality can be grasped by the said stud clamp.

8. The apparatus of claim 7 wherein the means for feeding includes a bar member mounted for movement along each of said rails, said bar member positioned to advance said plurality of studs toward said predetermined position, means for driving said bar member including a drive shaft mounted for rotation in each of said frame members, sprockets attached to said shaft for sliding movement thereon and to each of said frame members for rotating motion, a drive member operatively connecting said sprockets and said bar member and means for rotating said drive shaft.

9. The apparatus of claim 1 wherein said means for advancing comprises drive means for each plate, each drive means driven from a common shaft, a motor having a clutch and a brake on the clutch output shaft for transmitting power from said motor to said common shaft, means for sensing the arrival of a keyway at a predetermined location on each of said plates, and means responsive to a first output from said sensory means to actuate said clutch and responsive to a second output from said sensory means to actuate said brake.

10. An apparatus for producing wall panels by inserting studs having dovetailed male ends into spaced-apart plates having dovetailed keyways therein comprising:

two frame members mounted in a guideway on a base member for movement toward and away from each other,

first means attached to each of said frame members for advancing said plates and for positioning two of said keyways to simultaneously receive a said stud,

means for driving said first means which disengages from said first means responsive to the positioning of a first of said keyways,

means for stopping the advance of said tioning of a second of said keyways,

means operative upon positioning said keyways to receive a stud for inserting a stud into said keyways,

and means for supplying a plurality of studs to said means for inserting.

plates upon the posi-

Claims

1. An apparatus for production of wall panels formed from plates spaced apart by studs connected through joints including a female keyway comprising: two frame members mounted in spaced-apart relation on a base member; a plate guide mounted on each of said frame members, each substantially parallel to the other and each capable of receiving a plate having a plurality of dovetailed keyways formed therein, means for advancing said plates along said guides and including means for aligning consecutive keyways such that said keyways are capable of simultaneously receiving the ends of a stud, a stud clamp mounted for movement through a portion of an arcuate path whose axis of generation is parallel to the longitudinal dimension of the stud, said stud clamp mounted to grasp a preselected stud from a stack of studs and move the stud from the stack through said path to a temporary support, and a press means operative upon the arrival of said stud at said temporary support means for forcing said ends of said studs into said keyways.

10. An apparatus for producing wall panels by inserting studs having dovetailed male ends into spaced-apart plates having dovetailed keyways therein comprising: two frame members mounted in a guideway on a base member for movement toward and away from each other, first means attached to each of said frame members for advancing said plates and for positioning two of said keyways to simultaneously receive a said stud, means for driving said first means which disengages from said first means responsive to the positioning of a first of said keyways, means for stopping the advance of said plates upon the positioning of a second of said keyways, means operative upon positioning said keyways to receive a stud for inserting a stud into said keyways, and means for supplying a plurality of studs to said means for inserting.