Machine for assembling structures such as frames
[&#39; Apr. 15, 1975 MACHINE FOR ASSEMBLING [57] ABSTRACT A machine for the automatic production line assembly STRUCTURES SUCH AS FRAMES [76] Inventor: Marion 0. Fogle, Rt. 3, Box 377F,  
 Orangeburg, S.C. 291 15 Aug. 3, 1973 of a building structure such as a door frame having a pair of stiles and a pair of rails secured together in a [22] Filed:  
  rectangular configuration which includes a frame on PP 335,431 which are mounted hoppers in which the tiles and rails are positioned in vertically stacked relationship, the lowermost rails and stiles in the hoppers being moved inwardly by fluid pressure actuated cylinder-piston assemblies and clamped thereby into an assembled condition for subsequent stapling together at the joints by 0 RH mRo l lwo No 2 93 ZMBD u 000 &#34;00 m 22 m R R m 0 n O n 22 7 mm M mmmO 2 I n 9 m m h c n r u a u e u S III. I C s Umn Hum 555 staple guns mounted on the frame over the joints, the assembled structure being released by the clamping means for removal from the frame in a repetitive oper- [56] References Cited UNITED STATES PATENTS ation for the continuous production of such building structures.  
 10 Claims, 4 Drawing Figures Primary ExaminerThomas H. Eager a PR&#34;.  
 PATENTEDAPR 1 5197s SHEET 1 [IF 2 PATENTEDAPR 1 1915 3; 877. 132 sumanfz MACHINE FOR ASSEMBLING STRUCTURES SUCH AS FRAMES This invention relates to the building industry and move particularly to apparatus for constructing a building component. Many structures in the building industry utilize structural elements such as boards. panels. and the like which are assembled into a wide variety of shapes and sizes to form an assembled structure which may be used alone or in combination with other similarly fabricated structures. The accuracy with which such structures are built must be within reasonable limits and therefore the structural elements or component parts are generally assembled by hand or by means of a jig and secured together by gluing staple. nails or the like. Considerable time and labor is usually involved in the assembly of such building structures and, with the rising costs of labor and the amount of labor required for such fabrication work, considerable effort has been made to eliminate as much of the labor costs as possible by the use of specially designed machinery for carrying out such fabricating operations. However, the wide variety of types of such building structures do not economically justify special machinery for each type of structure. In addition, many types of such building structures are not suitable for mechanized assembly. An even greater factor to be considered is the tremendous cost and highly complex construction of such machines considering the many individual operations which such machines would be required to perform even on the simplest of building structures.  
 Accordingly, a primary object of this invention is to provide a new and novel apparatus for the fabrication of building structures.  
  Another object of this invention is to provide a new and novel machine for automatic assembly and fastening of structural elements into a rectangular building structure.  
  A further object of this invention is to provide a new and novel machine for the fabrication in a production line, repetitive type operation, a building structure which completely eliminates the need for manual labor.  
  This invention further contemplates a provision of a new and novel machine for fabricating a building structure such as a door frame or the like which is simple and inexpensive in construction, which is capable of high speed operation for the fabrication of such structures at a high production rate, which is composed of a minimum of parts and which is capable of prolonged use without breakdown.  
  A still further object of this invention is to provide a new and novel machine for the automatic fabrication of a door frame of the type utilized in hollow doors which is readily adjustable for fabricating such frames in a wide variety of shapes and sizes and which not only automatically feeds the frame components into the machine but automatically removes structures assembled by the machine to a remote location.  
  Other objects and advantages of the invention will become apparent from the following description taken in connection with the accompanying drawings.  
  In general, the objects of this invention and other related objects are accomplished by the provision of a substantially rectangular frame including a pair of side frame members arranged in spaced parallel relationship and a pair of end&#39;frame members arranged in spaced parallel relationship to define a central opening. Means are provided on each of the side frame members for supporting a plurality of elongated side structural elements in a vertically stacked, storage position and means are provided on each of the end frame members for supporting a plurality of end structural elements in a vertically stacked, storage position. The supporting means on each of the frame members include clamping means for moving the side and end structural elements inwardly from the storage position into an assembly psoition with adjacent portions of the elements in abutting engagement to form a building structure having joints. Fastening means are provided on the frame for securing the elements together at the joints to form an assembled building structure, the clamping means being arranged to release the assembled building structure for removal of the structure from the frame.  
  The novel features which are believed to be characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation may be best understood by reference to the following description taken in conjunction with the accompanying drawings in which:  
  FIG. 1 is a perspective view, partially broken away, of the apparatus of the invention;  
  FIG. 2 is perspective view of the building structure fabricated in the apparatus of FIG. 1;  
  FIG. 3 is a side elevation view of a portion of the apparatus of FIG. I at one stage in the operation of the apparatus;  
  FIG. 4 is a view similar to FIG. 3 illustrating the parts in a subsequent stage in the operation of the invention.  
  Referring now to the drawings, there is shown on FIG. 1 a machine constructed in accordance with the invention which is used for fabricating building structures such as a door frame designated generally in FIG. 2 by the letter D. It should be understood that although the apparatus of the invention will be described hereinafter for use in the fabrication of such frames D, any building structure of the type corresponding to the frame D may be produced with the machine of invention.  
  The door frame D is of the well known construction which is used as an inner frame or skeleton for what is referred to as a hollow door. The frame D includes a pair of end structural elements such as rails ll, 12, generally formed of wood or the like, and arranged in spaced parallel relationship. The frame D also includes a pair of side structural elements such as stiles l3, 14, also formed from wood or the like. In the illustrated embodiment, rails 11, 12, and stiles 13, 14, are fastened together by suitable means such as staples 16 although it should be understood that any suitable type of fastening means may be used such as hot melt adhesive or the like.  
  In the formation of a door using frame D, the interior of the frame is filled with reinforcing material such as a honeycomb insert and the frame is enclosed by a skin such as plywood panels on both faces to form a hollow door. In one hollow door construction, a lock block is utilized such as the lock block 17 shown in FIG. 2, the lock block 17 being formed from wood or the like and secured to one of the side structural elements such as stile 13 by means such as staples 18.  
  Referring now again to FIG. 1, the apparatus of the invention includes a pair of side frame members 21, 22 arranged in spaced parallel relationship and a pair of end frame members 23, 24 similarly arranged in spaced parallel relationship and secured to the side frame members 21, 22 by welding or the like. The .side frame members 21, 22 and end frame members 23, 24 form a frame of substantially rectangular configuration designated generally in FIG. 1 by the letter F. A conveyor 30 driven by suitable means (not shown) in the direction of the arrow I is disposed below the frame central opening 26 for a purpose to be explained hereinafter.  
  Means are provided on each of the side frame members 21, 22 for supporting at least one of the side structural elements or stiles 13, 14 in a storage position. Most specifically, the supporting means include a hopper on each of the side frame members 21, 22 designated generally by the numerals 27, 28 respectively. The hoppers 27, 28 are substantially identical in construction and hopper 27 includes a pair of upstanding channel members 29, 31 arranged in spaced relationship and suitably secured by welding or the like to the frame F adjacent the corners of the frame as shown best in FIG. 1. Preferably, the channel members 29, 31 are provided with reinforcing members 32, 33 secured by welding or the like to opposite sides of the channel members 29, 31 and the hopper 27 is arranged to accommodate in vertically stacked relationship, a plurality of stiles 13.  
  Similarly a pair of channel members 36, 3 7 are suitably mounted on the frame F adjacent the corners of the frame on the side defined by the side frame member 22. The channel members 36, 37 define there between the hopper 28 for accommodating a plurality of side structural elements or stiles 14in a vertically stacked, storage position. The channel members 36, 37 are similarly reinforced by cross members 38, 39 secured by suitable means such as welding or the like to the opposite sides of the channel members 36, 37.  
 Means are provided on each of the end frame members for supporting at least one end structural element such as the rails 11, 12 in a storage position. Most specifically, a pair of upstanding frame members 41, 42 are secured in laterally spaced relationship to the end frame member 23 together with upstanding frame members 43, 44 arranged in spaced parallel relationship with frame members 41, 42 respectively for defining a hopper 46 for accommodating at least one and preferably a plurality of end structural elements or rails 12 in the vertically stacked relationship as shown. Preferably, reinforcing member 47 is suitably secured to the frame members 41, 42 and additional support for the frame members 43, 44 is provided with L-shaped brackets 48, 49 suitably secured by welding or the like to the frame members 43, 44 and channel members 29, 36 respectively. 1 Similarly, a pair of upstanding frame members 51, 52 arranged in laterally spaced relationship are secured to the end frame member 24 together with upstanding frame members 53, 54 arranged in spaced parallel relationship with the frame members 51, 52 to define a hopper, designated generally by the numeral 56, for accommodating at least one and preferably a plurality of end structural elements such as rails 11 in a vertically stacked relationship as shown. Preferably, the frame members 51, 52 are provided with reinforcing member 57 and L-shaped brackets 58, 59 suitably secured to the frame members 53, 54 and to channel members 31, 37 respectively for supplemental of the hopper 56.  
  The supporting means for supporting the stiles l3, l4 and rails 11, 12 also include clamping means for moving the stiles and rails from the storage position of FIG. 1 into an assembly position with adjacent portions of the elements in abutting engagement to form a building structure such as the frame D. Most specifically, as shown best in FIG. I, each of the hoppers 27, 28, 46, 56 has operatively associated therewith a fluid pressure operated, cylinder-piston assembly designated generally by the numeral 61. Each of the cylinder-piston assemblies includes a cylinder 62 and a piston 63 and is connected to an associated source of fluid pressure through a suitable control valve (not shown) in the conventional manner.  
  Each cylinder-piston assembly 61 is preferably secured to a base plate 64 which is mounted on the associated side and end frame members 21-24 and on the frame F as shown by the frame portions designated generally by the numeral 66.  
  It should be understood that each cylinder-piston assembly 61 is substantially identical in construction and therefore like numerals will be used hereinafter to identify like parts.  
  Referring now specifically to FIGS. 3, 4, an L-shaped support plate, designated generally by the numeral 67, is secured to the outer end 63a of each of the pistons 63. The support plate 67 includes a horizontally extending plate portion 67a and a vertically extending leg portion 67b secured to the piston outer end 63a. It will be noted that, in the preferred embodiment the support plate 67 is thus positioned on the piston 63 below the upper surface 63b of the piston for a purpose to be explained hereinafter.  
  As is well know, the piston 63 is movable between the retracted position of FIG. 3 and the extended position of FIG. 4. In the retracted position of FIG. 3, the support plate is positioned beneath the associated hopper such as the hopper 27 of FIG. 3. Thus, the lowermost stile 13 of the vertically stacked stiles 13 in the hopper 27 is supported on the support plate 67 in the retracted position of the piston 63 and all of the pistons 63 are initially in the retracted position with the lowermost rails and stiles in the storage position prior to the operation of the apparatus of FIG. 1.  
  Although it should be understood that a door frame D of a type formed from stiles 13, 14 and rails 11, 12 only may be formed in the apparatus of the invention, in the illustrated embodiment, an auxiliary hopper 68 is provided for the type of door frame shown in FIG. 2 utilizing a lock block 17. The hopper 68 is preferably formed with a pair of channel members 71, 72 supported on the Frame F in spaced relationship as shown in FIG. 1 to provide auxiliary supporting means on the frame for supporting at least one intermediate structural element such as the lock block 17 in a storage position. The auxiliary hopper 68 is supported on the frame F adjacent thestructural elements supported on one of the side frame members such as the stiles 13 supported in the hopper 27 on the side frame member 21 as shown best in FIG. 3. A freely pivotal, downwardly depending flap member 70 is mounted on the lower end of the hopper 68 adjacent the hopper 27 for a purpose to be explained hereinafter. The auxiliary supporting means for the lock block 17 also includes the clamping means associated with the side frame member 21 which includes the support plate 67 on which the lowermost lock block 17&#39; in the stack of lock blocks 17 is supported asshown in FIG. 3.  
  The frame F also includes top means adjacent each of the end frame members 11, 12 for limiting the movement of the railsll, 12 to an assembly position within the interior of the frame F over the central opening 26. More specifically, a framework designated generally by the numeral 73 is suitably supported on the frame F, preferably on the upstanding frame members 53, 54 as shown adjacent the end frame member 24. The framework 73 includes downwardly depending spaced-apart legs 74, 76 which are arranged to be engaged by the rail 11 as will be explained hereinafter. Similarly, a framework 77 is supported on the frame F adjacent the end frame member 23 preferably on the upstanding frame member 43, 44 and includes a pair of downwardly pending leg portions 78, 79 for engagement by the rail 12 in the assembly position.  
  The apparatus of the invention includes fastening means on the frame F for securing the structural elements together to form an assembled building structure. Most specifically, in the assembled condition of the elements such as rails 11, 12 and stiles 13, 14, D joints, designated generally by the letter J, are formed by the elements where portions of the elements abutt. In the embodiment of FIG. 2, lock block 17 also forms a joint designated generally by the letter J with the stile 13.  
  Although, a hot melt adhesive or the like may be utilized, in the preferred embodiment staple guns of conventional construction each having a stapling head H are utilized to fasten the elements together. As shown best in FIG. &#34;1, the staple guns are preferably of the pneumatic type are automatically actuated by suitable control means (not shown). The staple guns S are supported on the frame F with the staple gun head H in overlying relationship with the joints J and J in the assembly position of the elements. It will be noted that preferably a pair of staple guns S are utilized for the lock block 17.  
  As shown best in FIGS. 3, 4, each of the staple guns S is provided with a laterally extending spring plate 81 suitably secured to the staple gun head H the spring plates 81 being arranged for overlying sliding engagement with the adjacent structural element during the movement of the structural element from the storage position into the assembly position. By means of the spring plates 81, the structural element such as rails 11, 12 and stiles 13, 14 are yieldingly guided and retained between the L-shaped plate number 67 and the spring plate 81 thus retaining the structural elements in the proper stapling position under the head H. ln order to retain the intermediate structural element or lock block 17 in the assembly position, a framework 82 having downwardly depending leg members 83 is suitably secured to the channel member 71, 72 of the hopper 68 the members 83 engaging the lock block 17 and limiting the movement of the lock block to the assembly position as it is moved from the storage position.  
  In the operation of the invention, rails 11, 12 are stacked in the hoppers 56, 46 respectively, stiles 13, 14 are stacked in the hoppers 27, 28 respectively and lock blocks 17 are stacked in the hopper 68 the lowermost structural element in each of the hoppers resting on the support plate 67 with the piston 63 of the assemblies 61 in the retracted position as shown in FIG. 3. It should be understood that FIG. 3 shows the cylinder-piston assembly associated with hoppers 27, 68 and that the other hoppers and cylinder-piston assemblies are similarly arranged.  
  By automatic actuation through suitable valve control means (not shown), the cylinder-piston assemblies 61 associated with hoppers 46, 56 are actuated to move the pistons 63 fromthe retracted position to the extended position in the manner shown in FIG. 4 to move the rails 11, 12 respectively against the stop members 74, 76 and 78, 79 respectively inwardly of the frame F into an assembly position over the central opening 26. Subsequently, the cylinder-piston assemblies 61 associated with hoppers 27, 28 are actuated to move the stiles l3, l4 inwardly so that the end portions of the stiles l3, l4 engage the ends of the rails 11, 12 to formthejoints J the subsequent structural elements in the hoppers dropping down onto the pistons 63 for a portion of its total drop as shown on FIG. 4. During the movement of the stile l3 inwardly into the assembly position, the lowermost lock block 17 is also moved ahead of the lowermost stile 13, the flap member 70 pivoting upwardly to retain the subsequent lock block 17&#34; within the hopper 68. The movement of the lowermost lock block 17&#39; and consequently the lowermost stile 13 is limited to the assembly position by the engagement with the stop members 83.  
  At this time all of the staple guns S are actuated injecting the staples 16, 18 into the respective joints J, J, forming the assembled building structure or door frame D. All of the pistons 63 are then retracted by suitable actuation of the cylinder-piston assemblies 61 so that the frame D falls downwardly through the central opening 26 in the frame F onto the conveyor 30 moving in the direction of the arrow l to convey the &#34;assembled frame D to a remote location. 1 i  
  As the pistons 63 return to the retracted position of FIG. 3, the subsequent rails, stiles and lock blocks drop onto the respective support plates 67 and the apparatus of the invention is ready for another assembly opera- 1 tion.  
  It should be understood that the apparatus of the invention may be made adjustable in many respects for fabricating various sizes and types of building structures. For instance, the hoppers 27, 28, 46, 56 and 68 may be provided with adjustable components so as to accommodate various sizes of stiles, rails and lock blocks. The frame F may itself be constructed for adjustably positioning the frame members 21-24 for the fabrication of various sizes and shapes of building structures such as door frame D. It is also desirable to mount the cylinder-piston assemblies 61 for adjustable positioning so as to calibrate the strokes of the pistons and insure the application of the optimum amount of retaining force exerted on the structural elements by the pistons in the assembly position.  
  While there has been described what at present is considered to be the preferred embodiment of the invention, it will be understood by those skilled in the art that various changes and modifications may be made therein without departing from the invention.  
 Having thus described the invention, what is claimed 1. Apparatus for fabricating building structures of the type having a pair of end structural elements and a pair of side structural elements comprising in combination, a substantially rectangular frame. including a pair of side frame members arranged in spaced parallel relationship and a pair of end frame members arranged in spaced parallel relationship means on each of said frame members for supporting at least one of said side structural elements in a storage position, means on each of said end frame members for supporting at least one of said end structural elements in a storage position, said supporting means including clamping means for moving said side and end structural elements from said storage position into an assembly position with adjacent positions of said elements in abutting engagement to form a building structure having joints, fastening means on said frame for securing said elements together at said joints to form an assembled building structure, said clamping means being arranged to release said assembled building structure for removal of said structure from said frame.  
  2. Apparatus for fabricating building structures in accordance with claim 1 including auxiliary supporting means on said frame for supporting at least one intermediate structural element in a storage position adjacent one side structural element supported on one of said side frame members, said clamping means associated with said one side frame member being arranged to move said intermediate structural element from said storage position into an assembly position together with said one side structural element and fastening means on said frame for securing said intermediate structural element and said one side structural element together in said assembled structure.  
  3. Apparatus for fabricating building structures in accordance with claim 2 wherein said auxiliary supporting means include an upstanding auxiliary hopper supported on said frame in aligned relationship with said supporting means on said one side frame member, said auxiliary hopper being arranged to support a plurality of said intermediate structural elements in vertically stacked relationship, a freely pivotal, downwardly suspended flap member on the lower end of said auxiliary hopper adjacent said one side frame member supporting means for upward pivotal movement into temporary supporting engagement with the subsequent intermediate structural element in said auxiliary hopper during the movement of the lowermost structural element in said one side frame member supporting means from said storage position into said assembly position and for downward pivotal movement for release of said subsequent structural element during the release of said assembled building structure by said clamping means and auxiliary stop means on said frame for limiting the movement of said intermediate structural element to said assembly position.  
  4. Apparatus for fabricating building structures in accordance with claim 1 wherein said supporting means includes an upstanding hopper on each of said side and end frame members, each of said hoppers being arranged to support a plurality of said structural elements in vertically stacked relationship and wherein said clamping means on each of side and end frame members is arranged to successively move the lowermost structural element in said hoppers from said storage position into said assembly position.  
  5. Apparatus for fabricating building structures in accordance with claim 4 including stop means on said frame adjacent each of said end frame members for limiting the movement of said end&#39;structural elements to said assembly position and wherein said clamping means on said side frame members if arranged to move said side structural elements into said assembly position subsequent to the positioning of said end structural elements in said assembly position to thereby permit said end structural elements to limit the movement of said side structural elements to said assembly position.  
  6. Apparatus for fabricating building structures in accordance with claim 5 wherein said side and end frame members define a central opening and including conveyor means disposed in underlying relationship with said frame and in alignment with said central opening, said central opening being arranged to permit said assembled building structure to move from said assembly position downwardly through said opening onto said conveyor means upon release by said clamping means.  
  7. Apparatus for fabricating building structures in accordance with claim 6 wherein said clamping means include a fluid pressure operated cylinder-piston assembly positioned on said frame adjacent each of said hoppers, an L-shaped support plate secured to the outer end of the piston of each of said cylinder-piston assemblies, each of said pistons being movable into a retracted position with said support plate in underlying relationship with the associated hopper to supportingly receive the lowermost structural element in said associated hopper corresponding to said storage position and into an extended position corresponding to said assembly position for forming said structural elements into said assembled building structure, each of said pistons being movable from said extended position to said retracted position to release said assembled building structure and permit said support plate to receive the subsequent structural element in said associated hopper.  
  8. Apparatus for fabricating building structures in accordance with claim 7 wherein said fastening means comprises a plurality of staple guns having a stapling head supported on said frame, each of said staple guns being disposed on said frame with said stapling head in overlying, operative relationship with one of said joints in said assembled building structure for stapling said structural elements together at said joint.  
  9. Apparatus for fabricating building structures in accordance with claim 8 including a laterally extending spring plate on each of said staple gun heads for overlying, sliding engagement with the adjacent structural element during the movement of said structural elements into said assembly position to yieldingly guide said structural element into underlying relationship with said head.  
 10. Apparatus for fabricating building structures in accordance with claim 9 wherein said L-shaped support plate includes a horizontal extending plate portion and a vertically extending leg portion having an upper end secured to said piston outer end to permit said piston to support said subsequent structural element during the movement of said lowermost structural element from said storage to said assembly position and to limit the downward movement of said subsequent structural element onto said support plate during the movement of said piston from said extended to said retracted position and including a spring disposed in encircling relationship with said piston between said cylinder and said support plate for yieldingly urging said structural elements together in said assembly position.