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