AUTOMATED CONSTRUCTION SYSTEM

• US 20120096702A1
• Filed: 09/11/2009
• Published: 04/26/2012
• Est. Priority Date: 09/14/2007
• Status: Abandoned Application

• Current Assignee: Alan Kingsley, Larry Bertelsen, Peter Miller, Richard Alan Roen
• Original Assignee: Alan Kingsley, Larry Bertelsen, Peter Miller, Richard Alan Roen
• Inventors: Kingsley, Alan, Bertelsen, Larry, Miller, Peter, Roen, Richard Alan
• Application Number:
  US12/558,470
• Publication Number:
  US 20120096702A1
• Time in Patent Office: Days
• US Class Current: 29/561
• CPC Class Codes: B23P 23/04 for both machining and other metal-working operations
• CPC Class Codes: E04B 1/35 Extraordinary methods of construction, e.g. lift-slab, jack-block E04B1/34 takes precedence; falsework, shuttering for shaping walls, floors, ceilings or roofs in situ E04G11/04; conveying or assembling of building materials E04G21/00; working measures on existing buildings E04G23/00
• CPC Class Codes: E04H 7/06 with vertical axis
• CPC Class Codes: Y10T 29/5122 with means to feed work during tool contact
• CPC Class Codes: Y10T 29/5143 and means to machine product
• CPC Class Codes: Y10T 29/5152 with turret mechanism

Abstract

An automated construction system is described. Embodiments of the automated construction system comprise an inner work station having at least one working level, and an outer work station having at least one working level, with industrial robots disposed on the outer or inner work station. The outer work station typically surrounds the inner work station, with a shaft disposed between the two work stations. A lift or hoist is provided for raising and lowering a work piece in the shaft. Embodiments of the present invention further comprise a carousel adapted to forming work piece sections from metal plate.

Claims

1. An automated construction system comprising:

an outer work station, the outer work station residing at about ground level;

an inner work station, the inner work station residing at about ground level;

a shaft, the shaft extending downwardly below ground level from an area residing between the inner work station and the outer work station; and

a hoist, the hoist being adapted to raise or lower in the shaft.

2. The automated construction system of claim 1, wherein the shaft is annular and surrounds the inner work station.

3. The automated construction system of claim 2, further comprising a rotation device, the rotation device being adapted to rotate the work piece around the inner work station.

4. The automated construction system of claim 1, wherein at least one of the inner work station or the outer work station comprises a robot adapted to perform an operation selected from the group consisting of welding, cutting, grinding, or testing.

5. A method of using the automated construction system of claim 4 comprising:

placing a first section on the hoist, the first section comprising a first cylindrical wall;

lowering the first section into the shaft;

placing a second section immediately proximate the first section, the second section comprising a second cylindrical wall; and

welding the second cylindrical wall to the first cylindrical wall.

6. The method of claim 5, wherein the welding the second cylindrical wall to the first cylindrical wall comprises a welding operation performed by the robot.

7. The method of claim 5, further comprising rotating a work piece around the inner work station, the work piece comprising the first tank section and the second tank section.

8. The method of claim 6, further comprising rotating the first section and second section in unison.

9. The method of claim 8, wherein welding the second cylindrical wall to the first cylindrical wall occurs while the rotating the first section and the second section in unison.

10. The method of claim 7, further comprising manually welding the work piece.

11. A method of using the automated construction system of claim 1 comprising:

using the hoist to lower a used oil tank into the shaft, the used oil tank being selected from a group consisting of oil storage tanks and oil production tanks;

working on an inside of the oil tank from the inner work station.

12. The method of claim 11, wherein the automated construction system further comprises a secondary shaft, the secondary shaft being continuous with and substantially parallel to the first shaft.

13. An automated construction system comprising a carousel, the carousel including a plurality of radial forming assemblies, the radial forming assemblies comprising rollers and being oriented in an array adapted to bend metal plate to form a closed figure shape.

14. The automated construction system of claim 13, further comprising:

an outer work station, the outer work station residing at about ground level;

an inner work station, the inner work station residing at about ground level;

a shaft, the shaft (i) being annular, (ii) surrounding the inner work station, and (iii) extending downwardly below ground level from an area residing between the inner work station and the outer work station; and

a hoist, the hoist being adapted to raise or lower a work piece in the shaft.

15. The automated construction system of claim 14, further comprising a rotation device, the rotation device being adapted to rotate the work piece around the inner work station.

16. A method of using the automated construction system of claim 13 comprising:

feeding the metal plate into the array;

bending the metal plate by pushing against a metal plate surface with one or more of the rollers;

simultaneously pressing at least two of the plurality of radial forming assemblies against the metal plate surface; and

forming the metal plate into a closed figure shape.

17. The method of claim 16, wherein one or more of the plurality of radial forming assemblies further comprises two or more horizontal members, the two or more horizontal members being coupled to the roller.

18. The method of claim 17, wherein:

the one or more of the plurality of radial forming assemblies further comprises an actuator arm, the actuator arm being coupled to at least one of the two or more horizontal members, and further comprising applying force to the at least one of the two or more horizontal members by a lengthening action of the actuator arm.

19. The method of claim 16, wherein the carousel further comprises feed rollers, the feed rollers comprising two or more parallel rollers, at least two of the two or more parallel rollers having parallel axes of rotation, and further comprising simultaneously pressing against opposite sides of the metal plate with the feed rollers.

20. The method of using an automated construction system comprising:

providing an automated construction system, the automated construction system including;

a carousel, the carousel comprising a plurality of radial forming assemblies, the radial forming assemblies comprising rollers and being oriented in an array;

an outer work station, the outer work station residing at about ground level;

an inner work station, the inner work station residing at about ground level;

a shaft, the shaft extending downwardly below ground level from an area residing between the inner work station and the outer work station;

a hoist, the hoist being adapted to raise or lower in the shaft;

feeding metal plate into the array;

bending the metal plate by pushing against a metal plate surface with one or more of the rollers;

simultaneously pressing at least two of the plurality of radial forming assemblies against the metal plate surface; and

forming the metal plate into a first cylindrical structure;

placing the cylindrical structure on the hoist;

lowering the cylindrical structure into the shaft;

placing a second cylindrical structure immediately proximate the first cylindrical structure; and

welding the second cylindrical structure to the first cylindrical structure.