Note: Descriptions are shown in the official language in which they were submitted.
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ASSEMBLY JIG AND USE THEREOF FOR ASSEMBLING DOME SECTION PANELS
CURVED IN TWO DIMENSIONS
Cross Reference To Related Application
0001 This is a continuation in part of Application No. 11/496,299 filed July
31, 2006,
in the name of Salah Eldeib, and entitled SYSTEM AND METHOD FOR MODULAR
CONSTRUCTION OF A DOME STRUCTURE AND ASSEMBLY COMPONENTS FOR
FACILITATING SAME, the entire contents of which are incorporated herein by
reference.
Field of the Invention
[0002] The present invention relates generally to a jig for assembling dome
section
panels curved in two dimensions.
Background of the Invention
[0003] Dome structures are noted for their strength and stability. They are
highly
hurricane resistant since they are aerodynamic and earthquake resistant as a
result of their ability
to distribute and efficiently dissipate the applied stresses. Monolithic dome
structures are
typically constructed by elaboration of a concrete ring foundation and require
that all tools and
machinery to be used are brought to the site of construction. A different
method of constructing
a dome structure involves creating a first circular segment, having a given
diameter and height,
which is secured to the ground. The circular segment itself is created by
connecting a plurality
of individual panels which are curved in both their length and height
dimension. Circular
segments having a successively decreased diameter are subsequently introduced
to complete
construction of a dome structure. This was disclosed in a previous patent
"System and Method
for Modular Construction of a Dome Structure and Assembly Components for
Facilitating
Same." It necessitates a method for preparing panels curved in two dimensions.
[0004] An assembly jig for assembling and preparing each panel curved in one
dimension was disclosed in Canadian Patent CA 1,228,976. The aforementioned
teaches an
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apparatus comprised of a series of parallel ribs which are connected together
and can be moved
simultaneously to create a curved surface for assembly of a panel. Since all
the ribs are
connected and move simultaneously as one unit, the apparatus suffers from the
limitation that the
curved surface can be in the form of a circular arc or an elliptical arc, but
not both. A more
significant limitation lies in the absence of a means for introducing or
accommodating curvature
in a second dimension. Thus, there is a need for an assembly jig that can be
utilized to prepare
panels curved in two dimension.
Summary of the Invention
[0005] The present invention addresses the need for a jig that can be employed
to
assemble a dome section panel that is curved in two dimensions. According to
the present
invention, an apparatus incorporates an odd number of guide arms that function
to guide and
secure the positioning of horizontal and vertical components while they are
being fastened to
form the section panel. In the preferred embodiment of the present invention,
each guide arm
possesses an arm carriage that houses a lower bracket and an upper bracket for
positioning lower
and upper plates, respectively, which define the frame of the curved section
panel. The
apparatus allows vertical components, which impart strength to the curved
section, to be
positioned between the lower and upper plates, oriented perpendicular to the
lower and upper
plates and fastened to the lower and upper plates. The brackets can be rotated
to accommodate
vertical components that are curved in their height (vertical) dimension,
which determines the
vertical curvature of the section panel.
[0006] In a preferred embodiment of the present invention, each ann carriage
is
supported by a base carriage. With the exception of the central base carriage,
each base carriage
can be moved independently along a curved path, such that the guide arms can
be arranged,
collectively, in the form an arc. This determines the curvature in the length
dimension of the
section panel. The location of the base carriages is adjusted according to the
desired spacing
between vertical components of an assembled curved panel and the desired
degree of curvature
in the length dimension of an assembled curved panel. Since each guide arm can
be moved
independently, the guide arms collectively provide a method for introducing
curvature either in
CA 02592893 2007-06-26
the form of a circular arc or an elliptical arc. Together, these unique
features allow a single
apparatus to be employed for the assembly of panels that are curved in two
dimensions.
Brief Description of the Drawin~s
[0007] Figure 1 is a perspective view of an assembled panel curved in two
dimensions.
[0008] Figure 2 is a side view of a vertical component (a "rib") to be
incorporated into
the panel.
[0009] Figure 3a is a side view of a rib and Figure 3b is a side view of a rib
with upper
frame plate, lower frame plate, and all shoulder plates fastened thereto.
[0010] Figure 4 is a perspective view of an assembly jig according to a
preferred
embodiment of the present invention.
[0011] Figure 5 is a side view of an assembly jig according to a preferred
embodiment of
the present invention.
[0012] Figure 6 is a elevation view of a guide arm according to a preferred
embodiment
of the present invention.
[0013] Figure 7 is a plan view of the assembly jig according to a preferred
embodiment
of the present invention.
[0014] Figure 8a is a elevation view of the first step in the process of
assembling a
curved panel according to a preferred embodiment of the present invention.
[0015] Figure 8b is a elevation view of the second step in the process of
assembling a
curved panel according to a preferred embodiment of the present invention.
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[0016] Figure 8c is a elevation view of the third step in the process of
assembling a
curved panel according to a preferred embodiment of the present invention.
[0017] Figure 8d is a elevation view of the fourth step in the process of
assembling a
curved panel according to a preferred embodiment of the present invention.
[0018] Figure 9 is a perspective view of an assembly jig according to a second
embodiment of the present invention.
Detailed Description of the Preferred Embodiments
[0019] The assembly jig according to the present invention is specifically
adapted for the
assembly of dome section panels curved in two dimensions. In order to
understand the present
invention, an exemplary assembled panel 20 curved in two dimensions is shown
in Figure 1.
The curvature in the length dimension of the assembled section panel is
indicated by the dashed
line. Each assembled panel includes an upper frame plate 22, a lower frame
plate 24, an upper
anterior shoulder plate 26, an upper posterior shoulder plate 28, a lower
anterior shoulder plate
30 and a lower posterior shoulder plate 32. The aforementioned plates 22, 24,
26, 28, 30 and 32
can be formed from any suitable engineering material, including OSB (oriented
strand board)
sheets, plywood, particle board, press board, plastic or steel. The length of
the aforementioned
plates determines the length dimension of the assembled curved section panel
20.
[0020] The upper 22 and lower 24 frame plates are fastened to vertical
components,
termed ribs 34. Ribs 34 can be formed from any suitable engineering material
showing suitable
strength characteristics. The height of the ribs 34 determines the height of
the assembled curved
section panel 20. A typical rib 34 is illustrated in Figure 2. Each end of rib
34 has a portion 36
cut-away on the anterior and posterior face that allows rib 34 to be nestled
between anterior and
posterior shoulder plates 26-32. The curvature in the height dimension of a
rib 34, which leads
to curvature in the height dimension of the assembled curved section panel 20,
is indicated by the
dashed line in Figure 2. Figure 3a illustrates a side view of rib 34 and
Figure 3b illustrates a side
view of rib 34 with continuous upper frame plate 22, continuous lower frame
plate 24 and
continuous shoulder plates 26-32 assembled thereto.
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[0021] A preferred embodiment of the assembly jig 40 is illustrated in Figure
4. The
assembly jig includes a plurality of guide arms 42 connected to a flat
horizontal surface 44.
Guide arms 42 function to position horizontal and vertical components during
the assembly of
curved section panels 20. An odd number of guide arms 42 are incorporated into
the assembly
jig 40. While a preferred embodiment of the present invention is described as
having seven
guide anns 42, it is within the scope of the present invention that the
assembly jig may
incorporate any suitable odd number of guide arms 42, specifically, five,
seven or nine guide
arms. In one of its aspects, the assembly jig 40 has all of its seven guide
arms 42 aligned in a
row along one of the edges of the horizontal surface 44, as illustrated in
Figure 5.
[0022] With reference to Figure 6, each guide arm 42 includes a base carriage
46 resting
on the horizontal surface 44 and an arm carriage 48extending from and
pivotally connected to
the base carriage. As shown in Figure 7, base carriage 46 of a central arm 42
is fixed in its
position on the horizontal surface 44. The remaining base carriages 46 are
movable along a
curved path 50 on the horizontal surface 44. Independent movement of each base
carriage 46 in
either direction along its respective path 50 is controlled by a suitable
mechanical means such as
a worm gear, hydraulic mechanism or pneumatic mechanism. In a preferred
embodiment of the
present invention, worm gears 52 (shown, for example, in Figure 5) are
operated manually,
although it is within the scope of the present invention that this operation
is automated. When
the assembly jig 40 is viewed from above, a concentric pattern of curved paths
50 is formed,
wherein the length and radius of curved paths 50 increases on moving from the
central guide arm
42 to the outermost guide arm 42, on both the right and left side of the
central guide arm 42, as
illustrated in Figure 7. The position of each base carriage 46 on its curved
path 50 is chosen
according to the desired degree of curvature in the length dimension and the
desired spacing
between ribs 34 of the assembled curved section panel 20.
[0023] Each arm carriage 48 can be rotated from its upright position, from 0
to 90
degrees, about an axis that lies perpendicular to the length of the arm
carriage 48. This rotation
path 54 is depicted in Figure 6. In a preferred embodiment of the present
invention, a cylindrical
rod 56 connected at one end to the arm carriage 48 is pivotally connected at
its other end to a
component on the base carriage 46 which bears a grooved bore that can receive
a worm gear 58.
Thus, rotation of the worm gear 58 effects rotation of the arm carriage 48.
While the worm gear
56 has been used in the preferred embodiment, any suitable mechanical means
for effecting
CA 02592893 2007-06-26
rotation of the arm carriage 48 can alternatively be employed. It is also
within the scope of the
present invention that rotation of the arm carriages be automated.
[0024] As illustrated in Figures 4 and 8, each arm carriage 48 includes a
lower bracket 60
which is fixed in its position on the arm carriage 48 and serves to position
components during
assembly of the curved section panel. Each arm carriage 48 further includes an
upper bracket 62
located at the terminal end of the arm carriage 48. It also serves to position
components during
the assembly of the curved section panel, and its position along the length of
the arm carriage 48
can be adjusted to accommodate different heights of ribs 34. In the preferred
embodiment of the
present invention, the position of the upper bracket 62 is adjusted by means
of a worm gear 64
(shown in Figure 64), although any suitable mechanical means for effecting
movement of the
upper bracket 62 along the length of the arm carriage 48 can be employed.
Lower bracket 60 and
upper bracket 62 can rotate from 0 to 20 degrees and from 0 to 15 degrees,
respectively, about an
axis that lies perpendicular to the length of the arm carriage 48. This
rotation allows the brackets
to accommodate ribs 34 curved in its height (vertical) dimension, indicated by
the dashed line in
Figure 2.
[0025] Prior to assembling the curved section panel 20, the height of the
upper bracket
62 on every arm carriage 48 is adjusted to match the height of ribs 34 (and,
consequently, of
plates 20) that are to be used in the assembly. The angle of each the lower
and upper bracket 60,
62 is then adjusted to match the curvature in the height (vertical) dimension
of ribs 34. The
angle at which arm carriages 48 lie is set to a predetermined value that
facilitates access to both
the lower and upper ends of ribs 34 during assembly. With the exception of the
central base
carriage 48, each base carriage 48 is moved to a predetermined position on its
associated curved
path 50, which will determine the required curvature, in the length dimension,
and the required
spacing between ribs 34 in the assembled curved section panel.
[0026] With reference to Figure 8a, the process of assembling a curved section
panel
begins with placement of the lower frame plate 24 along the lower bracket 60
of the arm
carriages 48. The lower frame plate 24 is held in place by a clamp (not shown)
positioned on
each arm carriage 48. The upper frame plate 22 is placed in the upper bracket
62 of the arm
carriages 48 and held in place by a clamp (not shown) positioned on the arm
carriage 48. The
clamps are known in the prior art and are not a feature of novelty in the
present invention. The
lower posterior shoulder plate 32 is placed in the lower bracket 60 and
fastened to the lower
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frame plate 24, as shown in Figure 8b. The upper posterior shoulder plate 28
is then placed in
the upper bracket 62 and fastened to the upper frame plate 22. As illustrated
in Figure 8c, one
rib 34 is placed longitudinally between the lower bracket 60 and upper bracket
62 of each arm
carriage 48, wherein the cut-away portion 36 at the lower and upper end of
each rib 34 is fitted
with the lower posterior shoulder plate 32 and upper posterior shoulder plate
28, respectively. In
a final step, the lower anterior shoulder plate 30 is place atop the row of
ribs 34 within the lower
cut-away portion 36 and the upper anterior shoulder plate 26 is placed atop
the row of ribs 34
within the upper cut-away portion 36, as shown in Figure 8d. The lower and
upper anterior
shoulder plates 30, 26 are then fastened to the ribs 34. The assembled curved
section panel 20 is
then removed from the assembly jig 40 and the process is repeated to form
additional assembled
curved section panels. It is also within the scope of the present invention
that the assembly and
fastening processes be performed through an automated system.
[0027] As shown in Figure 9, a second embodiment of the assembly jig is also
designed
for the assembly of dome section panels curved in two dimensions. With
reference to Figure 9,
the second embodiment of the assembly jig 70 includes five guide arms 72
arranged on a semi-
circular shaped support surface 74 and spaced equidistantly from each other.
Although the
second embodiment is illustrated as utilizing five guide arms 72, any odd
number of guide arms
can be utilized. Each of the five guide arms 72 includes a platform 76, a base
carriage 78 and an
arm carriage 80 pivotally connected to the base carriage 78. With the
exception of the central
guide arm 72 (which is centrally secured), platfonns 76 can be moved in either
direction along a
linear path (not shown) on the support surface 74. Further, each base carriage
78 moves along a
linear path (not shown) on its respective platform 76. In the second
embodiment of the present
invention, movement of base carriages 78 is effected by means of a worm gear
82, although any
suitable mechanical means can be employed. Since guide arms 72 are arranged in
a semi-
circular manner by virtue of the shape of the support surface 74, the assembly
jig 70 is
predisposed to assemble section panels curved in its length dimension. The
location of platforms
76 and base carriages 78 along their respective paths determines the degree of
curvature in the
length dimension and the spacing between ribs 34 of the assembled curved
section panel.
[0028] Each arm carriage 80 includes a lower bracket 84 and an upper bracket
86 for
positioning and securing horizontal and vertical components during the
assembly of the curved
section panel. The distance between the lower and upper brackets 84, 86 can be
adjusted to
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accommodate ribs 34 of different height, and brackets 84, 86 can be rotated to
accommodate ribs
34 that are curved in their height (vertical) dimension, as described in more
detail above with
respect to the first preferred embodiment of the present invention. Arm
carriages 80 can be
rotated from an upright position, perpendicular to the plane of the support
surface, from 0 to 90
degrees. In the second embodiment of the present invention, the aforementioned
movements are
effected by means of worm gears 88 and 90, respectively although any suitable
mechanical
means can be employed.
[0029] VWhile there have been shown and described and pointed out fundamental
novel
features of the invention as applied to preferred embodiments thereof, it will
be understood that
various omissions and substitutions and changes in the form and details of the
devices and
methods illustrated, and in their operation, may be made by those skilled in
the art without
departing from the spirit of the invention. For example, it is expressly
intended that all
combinations of those elements and/or method steps which perform substantially
the same
function in substantially the same way to achieve the same results are within
the scope of the
invention. It is the intention, therefore, to be limited only as indicated by
the scope of the claims
appended hereto.
