Apparatus for the fabrication of structural column members
[ Apr. 15, 1975 United States Patent 1 Dobson et al.  
 [54] APPARATUS FOR THE FABRICATION OF 3,711,919 H1973 29/200 P STRUCTURAL COLUMN MEMBERS Primary ExaminerThomas H. Eager [75 Inventors: Richard N. Dobson, Village of Creemore. Ontario; Gordon A.  
 Attorney, Agent, or Firm-Stanley J. Rogers Webster, Town of Dundas, Ontario, both of Canada ABSTRACT [221 Filed Jan 29 1973 The invention provides apparatus for the fabrication of a structural column member of solid cross-section which is rolled directly from a steel billet. The mem- {211 App]. No: 327,348  
  her is mounted in the apparatus which then permits Related Apphcauon Data the ends to be accurately squared; one end is then [62] Division of Ser. No. 220,297, Jan. 24, I972.  
 provided with two pins which are a close fit in holes in the other end of an abutting member. Two of these pins establish a theoretical axis which is used in another apparatus for locating brackets etc. fastened to D.. w m m ND. 3 m i 50 am al.-1m P w 02 08 2 H 2 &#34;H In H C nr &#34;3 9 &#34;ms L h m l d ud UmF N 555 the column member, despite any deviations of the 29/200 203 155 155 R member from straight. This theoretical axis is also used in assembling the members in a structure incorporating them.  
 [56] References Cited UNITED STATES PATENTS 29/200 P 5 Claims, 7 Drawing Figures 3.335.704 8/!967 Frecbourn.........................  
 APPARATUS FOR THE FABRICATION OF STRUCTURAL COLL&#39;MN MEMBERS CROSS REFERENCE TO RELATED APPLICATIONS The present application is a division of our applica tion Ser. No. 220.297 filed .lan. 2-l. I972.  
 FIELD OF THE INVENTION The present invention is concerned with improvements in or relating to apparatus for the fabrication of structural column members.  
 DESCRIPTION OF THE PRIOR ART The design and erection ofsteel structures. for example. for high-rise buildings employing straight column members subjected to high axial compression forces. has hitherto usually involved the design and fabrication of special rolled or custom built-up column sections. with the purpose of minimizing the weight of the structure. It has now been discovered that the use of columns comprising solid square or rectangular rolledsteel sections has distinct advantages of cost and ease of production. For example. such solid sections can be produced economically in a wide range of sizes in the slabbing mill of a steel plant. without requiring the use of expensive special shaping rolls and expensive aligning feed mechanisms.  
 DEFINITION OF THE INVENTION It is an object ofthe invention to provide new apparatus for the rapid and economical production of solidsection column members adapted for accurate installation into a steel structure.  
  In accordance with the present invention there is provided a new apparatus for the production of a structural column member constituted by an elongated steel billet of solid square or rectangular cross section. the apparatus comprising a base having a longitudinal axis. means for supporting one end of the member on the base by two spaced points or two spaced edges parallel to the said axis and engaging an end portion of the member. means for supporting the other end of the member on the base by a single point or a single edge parallel to the said axis and engaging an end portion of the member. and drilling jig fixtures for each end of the column member for guiding drilling mechanism in drilling coaxial first and second holes in the two ends of the member. each two coaxial holes establishing by being coaxial therewith corresponding first and second spaced. straight longitudinal axes for the column member accurately parallel to the said axis ofthe base. Preferably the said first axis constitutes a centre axis for the member.  
  Also in accordance with the present invention there is provided apparatus for the production of a structural column member constituted by an elongated steel billet of solid cross section and having at its opposite ends a first pin-receiving hole and a protruding first pin coaxial with a straight longitudinal first axis of the column member. the apparatus comprising a base. means for mounting the column member from the base for rota tion about a centre axis parallel to or coaxial with the said first axis. and means for mounting fixtures to be fastened to the surfaces of the column member against the said surfaces accurately positioned relative to a datum axis parallel to or coaxial with the first axis and at a predetermined distance therefrom.  
  In the application of the present invention it has been found that the geometry of the cross-section of the resultant structural member. which preferably is square or rectangular. together with the method of machining employed. permits more accurate workmanship than normally is possible in a fabricating shop using the above-mentioned built-up column. For example. it would be no more expensive to produce column members ofthe invention with holes centered to I (H cm in accuracy. than to provide built-up columns in the field with holes centered at i (LlSmm in accuracy. as with the current trade practices.  
  The new product obtained by use of this invention comprises a solid structural column member having special properties which permit quick and accurate fabrication and subsequent assembly. This is accomplished primarily by means of two straight. parallel. longitudinal axes established within the column member by two uniquely positioned and carefully drilled holes at each end of the member with the use of two close-fitting pins engaging in two of these holes in one end. These end holes thereafter provide reference locations for positioning attachments which are fastened to the column surfaces during shop fabrication. and later the holes cooperate with close-fitting pins for locating the column member in the building structure in order to provide. both in theory and practice. the greatest accuracy and rapidity ofassembly of one column member on top of another. The tolerances for location and clearance between each pin and the corresponding hole preferably is about I .(ll2cm to be effective. The close fit of the pins in the holes. together with their careful location at the ends of the column. provide the sole means for accurate mechanical assembly. without recourse to visual or other rough methods of alignment currently used.  
  The apparatus specified above as in accordance with the invention mounts the column member by means of two points or edges supporting one end of the column and one point or edge supporting the opposite end. and by means clamping each end of the column without distorting any natural bow or twistof the column. A drill jig fixture is used for drilling coaxial holes at the two ends o the column member. the axes of the coaxial holes constituting a predetermined straight centre line for the column member. despite the said bow or twist therein. and a second line exactly parallel to the central line.  
  The apparatus specified above as also in accordance with the present invention enables accurate rotational positioning of the column member about its central axis by use of predetermined locking stops in rotational supports at the column member ends. In this way the said two reference holes at each end ofthe column member are used for accurately positioning the column during shop assembly of attachments thereto and. as described hereinafter. for accurate and rapid assembly of a struc ture from the column membersin the field. both operations being of equal importance in achieving dimensional accuracy of the final building assembly.  
 DESCRIPTION OF THE DRAWINGS Particular preferred embodiments of the invention will now be described. by way of example. with refer&#39; ence to the accompanying diagrammatic drawings. wherein.  
  FIG. I is a perspectiw view of a new structural column member produced by use of apparatus in accordance with the invention ready for installation in a corresponding metal structure.  
  FIG. 2 is a general perspective view of an apparatus employed in the initial stages of the fabrication of a col umn member of FIG. 1.  
 FIG. Zu is a section taken on the line 20 2a of FIG.  
  FIG. 3 is a general perspective view of another apparatus employed in stages subsequent to those for which the apparatus of FIG. 2 is employed.  
  FIG. 4 shows a portion of the apparatus of FIG. 3 showing different auxiliary units that may be used therewith.  
  FIG. 5 is aside elevation of a column member and illustrates the operation of the invention. and  
  FIG. 6 is a perspective view to an enlarged scale of one end of the column member to illustrate a detail.  
  In all of the figures of the drawings parts are away as necessary for clarity of illustration.  
 DESCRIPTION OF THE PREFERRED EMBODIMENTS The structural column member 10 illustrated by the drawings is of square cross-section. but can also be of rectangular crosssection. and is formed by continuous casting or by hot rolling directly from a steel billet in the slabbing mill of a foundry. As an exantple only. such a member may have a length of about 4 to It) metres. while its cross-sectional area normally will measure from about 400 to 4.000 sqv cm. the maximum dimensions depending of course upon the capacity of the mill. Under present day mill practice it is acceptable that such a rolled member will deviate not more than I mm per mm of length from straight. In addition the member may be twisted along its longitudinal axis by an angle of up to about 3.  
  In a first stage of the process for the production of the completed member It) the column member is placed in the apparatus of FIGS. 2 and 2a comprising a rigid. accurate flat planar base II, on which two end fixtures l2 and l3 are mounted by an accurate longitudinal slot 14 for movement toward and away from one another in order to accommodate members of different lengths. One end fixture I2 is provided with a support member I5 providing two spaced longitudinal ridges (alternatively two spaced points may be used) on which the adjacent end portion of the column side face rests accurately parallel to the face of the base II and the slot 14. The other fixture [3 has a support member 16 provid ing only a single longitudinal edge (or point]. so that the adjacent end portion of the column side face will rest thereon. despite the presence of a twist in the column. as illustrated by FIG. 2a. The ends of the column are held firmly transversely in the fixtures by respective hydraulic motors l7 and 18. which press the column ends against respective stops 1) and 20.  
  End walls 2] and 22 of the fixtures l2 and 13 consti tute drilling jigs. each carrying drill guides 23 and 24. The two guides 23 are disposed very accurately coaxial broken with one another about a first common straight longitudinal axis 25 parallel to the longitudinal axis of the slot 14. while the two guides 24 are accurately coaxial with a second common straight longitudinal axis 26. all these axes being parallel to one another. two end walls 2] and 22 are shown as integral with their respective fixtures. but usually they will be removable. or otherwise adjustable. so that the positions and sizes of the drilling guides can be changed for use with different hole requirements of different members. With the col umn firmly clamped in the fixtures the column end faces 27 are formed accurately flat and parallel to one another to the degree of accuracy common in the industry. or. in the event that these faces have already been so formed. then their flatness and parallelism can again be checked and any necessary corrections made by use of a suitable tool. At the present time the requirement for flatness and parallelism is that when erected and under load any spacing between abutting end faces shall not be greater than 0.010 mm over 80% of the abutting bearing surfaces. Thereafter. a drill unit. such as the unit 28 shown in broken lines in FIG. 2. is used in conjunction with the guides to drill a first cen tral end hole 29 and a second side end hole 30 in each end of the column. Pins 3] and 32 are then pressed into the respective holes of one column end. these pins being close fits in the respective holes 29 and 30. preferably their diameter is from :t 0.01 cm to t 0.03 cm from the diameter of the corresponding hold.  
  Since the two holes 29 were formed accurately coaxial. the first common longitudinal axis 25 ofthe remaining central hole and the pin 30 will constitute a theoretical central longitudinal axis of the column even though. owing to bends and twists in the column. this usually will not coincide with the actual longitudinal axis. indicated for example in FIG. 5 by the reference 33. Similarly. the second common axis 26 of the remaining side hole 30 and the corresponding pin 32 is accurately parallel to the theoretical common axis 25.  
  The column is now at a stage in its fabrication for another step of the process to be applicable. using the apparatus of FIGS. 3 and 4. An accurate flat bed 34 carries two standards 35 and 36 which are employed to support the column for rotation about the longitudinal datum axis 25. Thus. the pin 31 engages in an axially movable carriage 37 on the standard 35. while the holes at the other end are engaged by respective pins on an arm 38 rotatably mounted on the standard 36. The arm is mounted on a shaft 39 which is in turn mounted by bearings for rotation about the axis 25, the rotation being produced by a mechanism illustrated diagrammatically and comprising a handle 40 driving via a connecting chain gear. A hydraulically operated adjustable-height strut 41 engages the column approximately at its midpoint to relieve the weight of the column and remove the downward deflection thereof.  
  The bed 34 also Carries two tracks 42 which are parallel to one another in both the horizontal and vertical planes. and are also parallel to the axis 25. A carriage 43 moves on these tracks in the direction of the arrows 43a. the position of this carriage longitudinally of the bed being set coaxially by means of a pin 44 which can be selectively engaged in a plurality of bores 45 accurately spaced equidistantly along the length of the bed. Fine adjustment of the carriage position is obtained by relative movement between the pin 44 and the carriage. the pin moving in an accurate edge slot 46 to at least the extent of an indicating scale 47. The carriage 43 also carries spaced transversely-extending parallel tracks 48 on which moves another carriage 49 in the direction of the arrows 49a. the position thereof radially relative to the axis being indicated by a scale 50 and cooperating pointer. The carriage 49 in turn carries four spaced parallel guide members SI extending perpendicular to the plane of the carriage and of the bed 34. the members supporting a carriage 52 for corresponding movement in the direction of the arrows 52a. under the action of a mechanism illustrated diagrammatically as comprising a worm gear 53 rotatable by a handle 54 and rotating a pinion 55 that rotates a threaded drive shaft 56. The vertical position of the carriage is indicated by scale 57 and pointer.  
  As illustrated in H6. 3 the apparatus includes two radially spaced jigs 58 for supporting respective connection brackets, the jigs being fastened to the carriage 52. each jig comprising a vertical standard 59 carrying a verticallyadjustable hydraulically-operated clamp member (10; a scale bl is used to indicate the vertical position of the clamp member. As illustrated in H6. 4 the carriage 52 supports two oppositely disposed drilling heads 62 whose function will be explained below. lt will be understood by those skilled in the art that the jigs 58 and the drill heads 62 may be interchangeable on a single carriage. or they may be fixtures to their respective carriages 52. the entire assembly front the car riage 48 on. or from the carriage 42 on. being duplicated and interchanged as required.  
  In operation of the apparatus of FIGS. 3 and 4. and completion of the process of the invention. the column member is mounted in the apparatus with its centre pin engaged in the carriage 37. and then is moved to the right as seen in FIG. 3. by a mechanism illustrated diagrammatically as comprising a handle 63 rotating a screw-threaded rod. until the centre hole 29 at the other end is engaged by the corresponding pin on the arm 38. At this time the arm is free to rotate relative to the remainder of its associated mechanism. so that it can be turned to engage the other pin thereon with the other hole 30 in the end of the column. while a cross-shaped member 6-3 is held stationary by a pin on the standard 36. the pin being selectively engageable with cooperating holes at the ends of the four arms of the member 64. With the second pin engaged in the hole 30 the arm 38 and the member 64 are connected for movement together. and the column can now be turned about its axis 25 to any one of four positions pre-set by the arms of the member 64 accurately at right angles to one another. and can be returned to any one of the four positions as required.  
  In the embodiment particularly illustrated it is desired to attach to each end ofthe column fixtures comprising four pairs of connection brackets 65. one pair to each of the four faces. with the connection brackets drilled to permit the fastening thereto of corresponding H-beams 66 that support the floors of the structure in which the column is incorporated. To this end each bracket 65 is in turn mounted in the two clamp members and then is brought by adjustment of the carriages into abutment with the corresponding face of the column member. but with its actual position determined solely by its relation to the axis 25 as set by the apparatus. and not by any relation between the bracket and the outside face contacted thereby. or by the actual longitudinal centre line of the column; the bracket is fill then welded securely in place. for example by use of a welding torch illustrated at 67. it will be seen therefore that all of the brackets can be fastened accurately spaced and accurately parallel relative to each other. within the limits of the apparatus. despite relathely severe distortions in shape of the column. by their common relation to the accurately-established common axis 25.  
  With all the brackets fastened in place the clamp members are replaced by the drilling heads 6] and the holes required for fastening the beams 66 thereto are drilled along axes 68 FlG. 5] that are accurately paral lel to one another and to the axis 25. The completed columns are thereafter transported to the side and erected by lowering them one on top of the other with the two pins ofeach lower column engaged in the holes of the column above. The centre pin in substantially longer than the side pin. so that it will enter its corresponding hole first; the column is then rotated on this pin. if necessary. until the rotational positioning side pin and hole register with one another. when the columns are brought completely together. Despite the number of columns piled one on top of the other. de spite differences in the straightness etc. of the individual column member. and despite differences in the cross-sectional area of the members. the resulting column establishes a common vertical axis 25 to which all fixtures to the column members are accurately related. so that other parts ofthe structure fastened to these fixtures will also be automatically accurately related to this axis. ln some embodiments neither of the axes 25 and 26 may be a centrallylocated axis of the column member. but nevertheless either will serve as the datum axis for accurate location ofthe theoretical centre line and for the location etc. of the fixtures.  
  The use of at least one pin. usually the central pin. of relatively large diameter closely fitted in a corresponding hole has an added advantage that it can of itself in some circumstances constitute all ofthe shearresisting connection that is required between abutting column members. obviating the need for additional side straps and brackets. etc. The ends ofthe pins protruding from the member preferably are tapered to facilitate their insertion in the respective holes; the hole entrances are bevelled for the same reason. such bevelling avoiding the possibility of metal being scraped from the side of the pins which ntight then become wedged between abutting columns and prevent proper seating therebetween.  
 We claim:  
  1. Apparatus for the production of a structural column member constituted by an elongated steel billet of solid square or rectangular cross section. the apparatus comprising a flat planar base having a longitudinal axis. means for supporting one end of the member on the base by two spaced points or two spaced edges parallel to the said axis and engaging an end portion of the member, means for supporting the other end of the member on the base by a single point or a single edge parallel to the said axis and engaging an end portion of the member. and drillingjig fixtures for each end of the column member for guiding drilling mechanism in drilling coaxial first and second holes in the two ends of the member. each two coaxial holes establishing by being coaxial therewith corresponding first and second spaced. straight longitudinal axes for the column member accurately parallel to the said axis of the base.  
  2. Apparatus as claimed in claim I. wherein the said longitudinal axis of the base is established b an accurate longitudinal slot therein.  
  3. Apparatus for the production of a structural column member constituted by an elongated steel billet of solid cross section and having at its opposite ends a first pinreceiving hole and a protruding first pin coaxial with a straight longitudinal first ads of the column member. the apparatus comprising a base. means for mounting the column member from the base for rotation about a centre axis parallel to or coaxial with the said first axis. and means for mounting fixtures to be fastened to the surfaces of the column member against the said stirfaces accuratel positioned relati\e to a datum axis parallel to or coaxial with the first axis and at a predetermined distance therefrom.  
  4. The imention as claimed in claim 3. wherein means for mounting the column member to the base comprise a first standard receiving a protruding pin of fill the member and a second longitudinally spaced standard comprising an arm member providing two spaced pins engageable in the corresponding holes in the end of the column member. the said arm member being rotatable and provided with means establishing four rotational positions of the column member accurately at right angles to one another and corresponding to respective longitudinal faces of the colunm member.  
  5. The imcntion as claimed in claim 3. wherein the said means for mounting fixtures are mounted to the base b three eo-operating carriages. one carriage being mounted for movement relative to the base in the plane thereof and parallel to the datum axis. a second carriage being mounted for movement transverse to the said axis in the plane of the base and the third carriage being mounted for movement transverse to the said axis perpendicular to the plane of the base.