PROCESS FOR MANUFACTURING WALL ELEMENTS FROM NAILABLE AND/OR STAPLEABLE MATERIALS

Abstract

A process for manufacturing wall elements from nailable and/or stapleable materials, in which a wall element frame is positioned on a horizontal worktable. Wall panels are placed on the frame and the wall panels are fastened to the frame by nails and/or staples, which are driven by a compressed air setting device. A mobile robotin particular an autonomous mobile robothas a compressed air setting device and/or at least one milling unit and is movable on the surface formed by the wall panels. The robot motion is automatically controlled along the surface formed by the wall panels. At predetermined positions, the milling unit and/or the compressed air setting device is actuated to process the wall panels and/or to fasten them to the wall element frame.

Claims

1. Process for manufacturing wall elements from nailable and/or stapleable materials, in particular wood or wood composite materials in which a wall element frame (5) of a wall element to be produced is positioned lying on a horizontal worktable (1), wall panels (6) are placed on the wall element frame (5), and the wall panels (6) are fastened to the wall element frame (5) by nails and/or staples which are driven in by means of a compressed air setting device (8), wherein a mobile robot (7)in particular an autonomous mobile robotcarrying at least one compressed-air setting device (8) and/or at least one milling unit (9) is freely movably positioned on the surface formed by the wall panels (6) being in contact with the latter, and the robot (7) is moved automatically controlled by the central controller (4) along the surface formed by the wall panels (6) and at predetermined positions the at least one milling unit (9) and/or the at least one compressed air setting device (8) is actuated automatically controlled by the controller (4) in order to process the wall panels (6) and/or to fasten them to the wall element frame (5).

2. Process according to claim 1, wherein the position and/or the shape of the wall element frame (5) are detected by means of an optical detection device (3) and corresponding data are transmitted to the central controller (4).

3. Process according to claim 2, wherein the wall element frame (5) and its position are displayed on a screen (11) on the basis of the data transmitted by the optical detection device (3), in particular desired positions of wall openings being marked on the screen (11) in addition to the position of the wall element frame (5) and/or the wall panel elements (6).

4. Process according to claim 2, wherein a travel path of the robot (7) is calculated by the controller (4) on the basis of the data transmitted by the optical detection device (3) and the robot (7) is moved in an automatically controlled manner by the controller (4) along the travel path.

5. Process according to claim 3, wherein a travel path of the robot (7) is calculated on the basis of the data transmitted by optical detection device (3) and is displayed on the screen (11), a user being given the possibility of correcting the travel path of the robot (7) on the screen (11), and then the robot (7) is moved automatically controlled along the corrected travel path.

6. Process according to claim 3, wherein a user is given the possibility of marking a desired travel path of the robot (7) on the screen (11) and the robot (7) is moved along the marked travel path in an automatically controlled manner.

7. Process according to claim 3, wherein the user is given the possibility of defining machining positions and/or machining paths for the at least one milling unit (9) and/or the at least one compressed air setting device (8) on the screen (11) and the robot (7) and/or the milling unit (9) and/or the at least one compressed air setting device (8) are driven and actuated in a controlled manner in accordance with the defined machining positions and/or machining paths.

8. Process according to claim 2, wherein the at least one milling unit (9) and/or the at least one compressed air setting device (8) is automatically actuated on the basis of the data transmitted by the optical detection device (3) in order to machine the wall panels (6) and/or to fasten them to the wall element frame (5).

9. Process according to claim 1, wherein an optical detection device (3) is used which comprises a plurality of cameras and/or laser detection devices which are provided in particular above the worktable (1).

10. Process according to claim 1, wherein the wall element frame (5) is provided with the wall panels (6) on both sides, the wall element frame (5) being turnedafter the wall panels have been fitted on one side of the wall element frame (5)and being covered with wall panels (6) on the open side which are finally fixed and/or machined on the wall element frame (5) automatically controlled by the robot (7) and the at least one compressed air setting device (8) and/or the at least one milling unit (9) on the wall element frame (5).

11. Processing device for manufacturing of wall elements from nailable and/or stapleable materials, in particular according to a process according to claim 1, with a horizontal worktable (1) on which a wall element frame (5) of a wall element to be produced can be positioned lying, a mobilein particular autonomousrobot (7) which carries at least one compressed-air setting device (8) and/or at least one milling unit (9), an optical detection device (3) adapted to detect the position and/or the shape of the wall element frame (5), and a central controller (4) which is coupled to said optical detection device (3), to said robot (7) and to the compressed air setting device (8) and/or the milling unit (9) and which is adapted to automatically move said robot (7), which is positioned on a surface formed by wall panels (6), which are placed on a wall element frame (5) positioned on the worktable (1), in contact therewith on the basis of data received from said optical detection device (3) on the surface and to automatically actuate the at least one milling unit (9) and/or at least one pneumatic setting device (8) at predetermined positions in order to machine the wall panels(6) and/or fasten them to a wall element frame (5).

12. Processing device according to claim 11, wherein a screen (11) on which an image of the wall element frame (5) and its position on the worktable (1) is displayed on the basis of the data transmitted by the optical detection device (3) is connected to the controller (4).

13. Processing device according to claim 12, wherein the controller (4) is designed to calculate a travel path for the robot (7) on the basis of the data transmitted by the optical detection device (3) and to automatically move the robot (7) along the travel path.

14. Processing device according to claim 12, wherein the controller (4) is designed to calculate a travel path for the robot (7) on the basis of the data obtained from the optical detection device (3) and to display the travel path on the screen (11), it being possible to correct the travel path of the robot (7) manually, and the controller is designed to move the robot (7) automatically in a controlled manner along the corrected travel path.

15. Processing device according to claim 13, wherein the screen (11) is designed for direct data inputin particular as a touchpadand a user is given the possibility of marking a desired travel path of the robot (7) on the screen (11), the controller (4) being designed to move the robot (7) automatically in a controlled manner along the marked travel path.

16. Processing device according to claim 12, wherein the screen (11) is designed for direct data inputin particular as a touchpadand a user is given the possibility of defining machining positions and/or machining paths for the at least one milling unit (9) and/or the at least one compressed-air setting device (8), the controller (4) being designed to move and actuate the robot (7) and/or the milling unit (9) and/or the at least one compressed-air setting device (8) in a controlled manner in accordance with the defined machining positions and/or machining paths.

17. Processing device according to claim 11, wherein the optical detection device (3) comprises a plurality of cameras and/or laser detection devices which are provided in particular above the worktable (1).

18. Process according to claim 3, wherein a travel path of the robot (7) is calculated on the basis of the data transmitted by the optical detection device (3) and the robot (7) is moved in an automatically controlled manner along the travel path.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In the drawing:

[0029] FIG. 1 is a schematic view in perspective of a worktable with associated cameras of a processing device for producing wall elements from nailable and/or stapleable materials according to the present invention in perspective view;

[0030] FIG. 2 is a schematic view in perspective of the arrangement of FIG. 1, wherein a wall element frame of a wall element to be produced is placed on the worktable,

[0031] FIG. 3 is a schematic view in perspective of a view corresponding to FIG. 2, with three wall panels positioned on the wall element frame,

[0032] FIG. 4 is a schematic view in perspective of the arrangement of FIG. 3, with a robot being placed on the surface formed by the wall panels, and

[0033] FIG. 5 illustrates a tablet PC and an input device therefor of the processing device according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0034] FIGS. 1 to 4 show the working steps of an embodiment of the process for manufacturing wall elements from nailable and/or stapleable materials by means of a corresponding processing device in accordance with the present invention. The inventive processing device for manufacturing wall elements comprises a horizontal worktable 1 which defines a horizontal supporting surface of rectangular basic shape, positioning/location projections 2 being provided along one longitudinal side and along one transverse side of the worktable 1, projecting upwards above the working surface of the worktable 1 and serving as a positioning aid. The processing device also comprises an optical detection device 3, which here comprises two cameras which are positioned above the worktable 1 and fastened, for example, to the ceiling of a machine hall or a suitable supporting structure. The optical detection device 3 detects the position and shape of workpieces positioned on the work surface of worktable 1. The optical detection device 3 is coupled with a central controller 4 of the processing device, which is preferably a tablet PC.

[0035] To manufacture a wall element, a wall element frame 5 is first positioned on the worksurface of worktable 1 and brought into contact with the positioning projections 2 and aligned in this way. The wall element frame 5 consists of a multitude of solid wooden struts 5a, 5b, 5c . . . , also called wooden stands, which are usually nailed together. In principle, it is also possible to position the individual wooden struts 5a, 5b, 5c . . . on worktable 1 and assemble them together to form the framework shown in FIG. 2, which has the necessary rigidity and statics. The shape and position of the wall element frame 5 is recorded by the cameras of the optical detection device 3 and transmitted to the controller 4.

[0036] In a further step, the upper side of the wall element frame 5 is planked, i.e. three wall panels 6 are laid on the wall element frame 5 so that they form a closed surface.

[0037] In a further step the wall panels 6 are fastened to the wall element frame 5 by nails and/or staples, which are driven into the wall panels 6 and the wall element frame 5 by means of a compressed air setting tool. In addition, window openings can be made in the wall panels or projecting panel edges can be trimmed.

[0038] According to the invention, these work steps are carried out by a mobile autonomous robot 7, which carries the processing equipment necessary for the operations to be carried out and is automatically controlled and moved on the surface formed by the wall panels 6 in order to carry out the operations. In FIG. 4, the robot 7 is positioned on the right wall panel 6 and carries an air pressure setting device 8, with which nails or staples can be set pneumatically to fix the wall panels 6 to the wall element frame 5, and a milling unit 9, which is used to cut out window openings from the wall panels 6 or to trim protruding panel edges. On the robot 4 is provided a processor which communicates with the controller 4 in a wireless way and is connected to a motor(s) of the robot 7 as well as with the air pressure setting device 8 and the milling unit 9 in order to move the robot 7 and activate the air pressure setting device 8/the milling unit 9 on the basis of data/commands received from the controller 4.

[0039] The robot 7 is assigned an enclosure 10, which is positioned outside the worktable 1. The robot 7 returns to this enclosure 10. The enclosure 10, into which the robot 7 withdraws after work, should protect the robot 7 from dust and at the same time be the transport packaging for the robot 7 in which it is delivered.

[0040] The enclosure 10 is height-adjustable and can be positioned so that the upper side of the wall panels 6 is approximately flush with the installation surface of the enclosure 10, so that the robot 7 can easily be moved into the enclosure 10 or from the enclosure 10 onto the wall panels 6.

[0041] The enclosure 10 can be designed as a loading station for the robot 7. Alternatively, the robot 7 can receive a permanent power supply, for example from the ceiling. In particular, the power can be supplied from the ceiling together with a compressed air line to supply the compressed air setting tool 8.

[0042] The tablet PC/controller 4 comprises a screen 11, which simultaneously functions as an input unit for the controller 4. As shown in FIG. 5, the screen 11 of the controller 4 displays an image of the wall element frame 5 as captured by the optical detection device 3. In other words, the image of the wall element frame 5, which resembles a frame work, is simulated on screen 11. At this point it is possible to influence the path of the robot 7. Machining operations and positions for the milling unit 9 or the pneumatic setting tool 8 can also be entered here.

[0043] The processing device according to the invention can be operated fully automatically. In this case, on the basis of the data received from the optical detection device 3, the controller 4 calculates the paths to be covered by the robot 7 in order to cover the entire wall element frame 5 and fix the wall panels 6 to the wall element frame 5 by means of nails or staples driven in by the air pressure setting device 8. Here it can be stored in the controller 4 at which fastening positions nails/staples must be driven into the wall panels 6 and the wall element frame 5 by the compressed air setting tool 8, i.e. the robot 7 must be stopped if necessary and the compressed air setting tool 8 must be actuated. It can also be stored along which paths the robot 7 must be guided and the milling unit 9 must be actuated in order to trim the panel edges or to make window openings in the wall panels 6.

[0044] Via screen 11, it is also possible to manually enter the travel paths for robot 7. In the same way, it is also possible to determine manually at which points a milling machining is to be carried out.

[0045] In addition, a hermaphroditic solution is possible, according to which the controller 4 suggests a travel path for the robot 7, fastening positions, etc. and the user has the possibility of manual influence.

[0046] Finally, the robot 7 is activated by the controller 4 and then moves from the loading station 10 onto the surface formed by the wall panels 6 and is moved along the paths defined by the defined travel path in order to position the milling unit 9 and the compressed air setting device 8 so that they can carry out the necessary work at the desired matching points. At these matching points, the milling unit 9/the compressed air setting device 8 are activated via the controller 4/the processor of the robot 7 to carry out the necessary work. The robot 7 is detected by the cameras of the optical detection device 3, and the robot 7 is moved in a controlled manner on the basis of the data determined by the optical detection device 3 and transmitted to the controller 4.

[0047] As best shown in FIG. 5, a stylus 20 is adapted for communication with the controller 4 though the screen 11. The tablet computer of the controller 4 and the stylus 20 are available, such as from Wacom Co., Ltd. of Japan. Illustrated on screen 11 is a wall element frame 5 formed from a plurality of interconnected wood or wood composite members 22. A window opening 24 can be seen in the wall element frame 5. The wall element frame 5 may either be shown on screen 11 because it is an image stored in memory and easily displayed on screen 11, may be drawn on screen 11 through movement of the stylus 20 on the screen 11 through use of a suitable drawing program, or may be captured by the optical device 3. The drawing program may be resident in the memory of controller 4. The computer program may, for example, be a computer aided design (CAD) program.

[0048] Once the wall frame element 5 is displayed on the display 11, the appropriate path for the robot 7 to move about the wall panels 6 may be either input through stylus 20 or calculated by the processor 4, and then transmitted to robot 7.

[0049] Once the wall frame element is displayed on the screen 11, the user may actuate another program in order to identify the boundaries of the wall frame element 5 and also the position of the interconnected members 22. Location of the interconnected members 22 allows the user to identify those members 22 that may be receive the staples or nails from the pneumatic setting tool 8. Further, location of the window opening 24 also identifies where the milling unit 9 is to operate in order to create the window opening 24. Of course, there may be multiple window openings 24, each identified through use of stylus 20. Those skilled in the art will understand that actuation of the pneumatic device 9 causes nails or staples to be driven through the panels 6 in order to secure them to the members 22, and thus to the wall frame member 5. Likewise, actuation of the milling unit 9 causes openings to be formed in the panels 6 in order to locate window opening 24 and ultimately for positioning of an appropriate window.