Complete factory for production of volumetric houses in timber frame. The factory consists of wall production, floor production, roof production line and mounting line.

 

 

 

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Click here for technical specification with pictures!

 

Comments to video:

Time                Station     
00:08-00:55    30   
01:00-01:10    31+32   
01:13-01:34    61   
01:40-02:29    31+32   
02:37-02:41    33   
02:42-03:18    34+35   
03:18-03:36    50   
03:36-03:47    51   
03:47-03:59    52   
03:59-04:03    86C   
04:03-04:09    53   
04:09-04:20    54   
04:22-04:24    53   
04:31-04:47    54   
05:03-05:23    36   
05:23-05:28    37   
05:28-05:38    38   
05:38-05:49    61   
05:58-06:29    38   
06:30-06:47    39   
06:47-06:52    86C   
06:52-07:03    40   
07:03-07:53    43   
07:54-08:15    44 + 45   
08:17-08:22    41   
08:43-08:50    60   
08:53-08:59    20   
08:59-09:16    21   
09:16-09:20    86C   
09:26-09:36    22   
09:36-09:45    23   
09:45-09:57    24   
09:57-10:03    not included
10:08-end       not included

 

House factory for production of volumetric prefabricated houses

Wall dimensions
Length:        Min. 1600, max. 10 800 mm.
Height:        Min. 2400, max  3200 mm.

Wall design
Y-walls from inside and out
13 mm gypsum sheet
15 mm protect-F
0,2 mm plastic cover
45 x 220 mm beams c/c. 600 mm.
220 mm mineral wool.
30 x <= 130 mm beam
<= 130 mm mineral wool
Wind cover paper

K-walls from inside and out
2 x 13 mm gypsum sheet
45 x 120 alt. 145 mm beams c/c. 600 mm.
120 alt 145 mm mineral wool
2 x 13 mm gypsum sheet

LS-walls from inside and out
13 mm gypsum sheet
15 mm protect-F
45 x 95 mm beams c/c. 600 mm.
95 mm mineral wool

The sheet material is placed at the outer dimensions of the wall element

General
The production line is optimized for production of Y-walls, K-walls and LS-walls. The building element is produced with the inside of the building element upwards.


Wall production line

Position 20     TTU2000-108, no. 1 Upraiser, buffer station
Hydraulic upraiser of for turning of building element to position 21, two fixed flat chain conveyors for transportation in the length direction of the building element.

Position 21    TTR2000-108, no.2 Receiver, buffer station
Hydraulic receiver for turning of building element from position 20, two fixed flat conveyors for transportation in the length direction of the building element. The cycle time of the turning max. 90 s.

Position 22     Upraiser
Technical description
The station is hydraulic upraisable to 90°.
The building element is transported into the station on two flat conveyors.

The station is also equipped with tip over support that is installed in the roof of the facility and rails that is installed on the floor. The station has pneumatically foldable horns.

Functional description
Two wagons placed on rails, the building component is raised, the foldable horns are brought into a down position and the building component is hereby put on the wagons.
The station is in a upraise position as the building component is manually pushed into the transfer wagon.
Position 23    Transfer wagon
The wagon is mobile with motor transport of building components from the production line to the existing stock.
The building components are transported manually into the transfer wagon on small wagons.
It is also possible to mount inner window flanning.
The support for the building component is adjustable for K-walls and LS-walls.
The transfer wagon is supplied with steel gantry covered with particle board for placement of working stations.

Position 24     Stock
The stock system according the following specification. The stock has capacity for 40 wall elements with max length of 8,5 m. 19 stock positions with variable width. 19 floor rails with length 16 800 mm and 80 wagons that the walls can be placed on. The rail is designed with flanges in order to enable flange control. The wagons are 200 mm in length and have 2 pairs of wheels and are equipped with stud. The wagons are controlled from above from each side of the profile 60 x 40 mm, length 12 000 mm and can store walls from 2400 mm to 3020 mm. The control profiles are screwed into a C-rail and can be adjusted collaterally and are suspended on 3 portal beams with 4 m in distance between the columns. The outer width of the stock is 5,5 m.

Combined production line for floor element and roof element

Floor element dimensions:
Length:        Min. 3600 mm. Max 10 800 mm.
Width:        Min. 3000 mm.  Max 4300 mm.
Beam dim:        Min. 120 mm.    Max 145 mm. Width 45 mm.
Insulation:        Mineral wool.

Sheets:
Particle board    22 mm.
Floor gypsum    13 mm.
Plywood        12 mm, bottom

Floor element dimensions:
Length:        Min. 3600 mm. Max 10 800 mm.
Width:        Min. 3000 mm.  Max 4300 mm.
Beam dim:        Max 220 mm. Width 45 mm.
Insulation:        Mineral wool.
Sheets:
Protect        15 mm.
Gypsum        13 mm.

Position 30     FM1000-108 Framing Station

The machine is designed for production of frame works for building elements and is designed with one fixed side and one movable for adjustment of different wall heights. The set up is manual with support of visual measure scale.

Technical description
The machine is equipped with “tiger stop/position stop” which enables correct c/c measures. 4 tool wagons for nailing guns (nailing guns are not included in quotation). The nailing guns are manually adjustable. The nailing is done with up to 4 nails in each nailing sequence. The nailing is done automatically when initiated by the operated. 2 roll support for in feed of top and bottom plate.

Functional description
The operator places top and bottom plate and fix them with the pneumatic cylinders by pushing a button. Afterwards the beam is placed against the pneumatically driven stops and fixated by pushing a button. When the top and bottom plate is fixated and controlled to be in the right position the operator activates the nailing sequence. The beam is nailed with 1 – 4 nails on each side depending on the set up. After the nailing sequence the frame is loosen from the fixated position and the operator pushes the frame work forwards to the next framing position and fixates it. The operator places a new beam in the right position fixates it and initiates the next nailing sequence.


Position 31     Nailing Station NT2000-108
The station has 3 driven flat chain conveyors for in feed and out feed of building element. One chain is on the adjustable side that is motor controlled for width adjustment and correction of building element angle and position wise. The station has pneumatically stops and pneumatically system that guarantees 90° of building element.

Position 32     Nailing Bridge NB2000-108
Working station for nailing of sheets. The bridge is motor driven and runs on rails on the floor. The bridge is equipped with 4 tool wagons for placement of 1 tool on each wagon. Each tool wagon is individually driven with motor. The tools are individually adjustable in height with a motor driven actuator.
     
Vertically nailing (y-axis) in the beams each tool nails ¼ of the height of the building element. The operator runs the bridge with a joystick and stops at the first beam position. After pushing the button the vertical nailing is done automatically. The operator afterwards runs the bridge to the next beam and the automatically nailing sequence is repeated.

Horizontally nailing (y-axis) the tools are moved to top or bottom plate, alternatively to position for beam over and beneath window.

The nailing pattern is programmable on the PLC.

Position 33     Working Station WT 2000-108, Buffer Station
The station has 2 driven flat chain conveyors for in and out feed of building elements. One chain is on the adjustable side that is motor driven for width adjustment and correction of building element angle and position wise.

Position 34     Butterfly Table, uppraiser TTU2000-108
The station has 2 driven flat chain conveyors for in and out feed of building elements. Hydraulic appraisable to 93° for turning of building element.

Position 35     Butterfly Table, receiver TTR2000-108
The station has 2 driven flat chain conveyors for in and out feed of building elements. Hydraulic appraisable to 87° for turning of building element. The station is motor driven for distribution to floor and roof production lines.

Position 36     Working Station WT 2000-108
The station has 2 driven flat chain conveyors for in and out feed of building elements.
One chain is on the adjustable side that is motor controlled for width adjustment and correction of building element angle and position wise. The station has pneumatically stops and pneumatically system that guarantees 90° of building element.

Position 37     Nailing Station NT2000-108
The station has 3 driven flat chain conveyors for in feed and out feed of building element. One chain is on the adjustable side that is motor controlled for width adjustment and correction of building element angle and position wise. The station has pneumatically stops and pneumatically system that guarantees 90° of building element.

Position 38     Nailing Bridge NB2000-108
 Working station for nailing of sheets. The bridge is motor driven and runs on rails on the floor. The bridge is equipped with 4 tool wagons for placement of 1 tool on each wagon. Each tool wagon is individually driven with motor. The tools are individually adjustable in height with a motor driven actuator.

Vertically nailing (y-axis) in the beams each tool nails ¼ of the height of the building element. The operator runs the bridge with a joystick and stops at the first beam position. After pushing the button the vertical nailing is done automatically. The operator afterwards runs the bridge to the next beam and the automatically nailing sequence is repeated.

Horizontally nailing (y-axis) the tools are moved to top or bottom plate, alternatively to position for beam over and beneath window.

The nailing pattern is programmable on the PLC.

Position 39     Working Station WT 2000-108
The station has 2 driven flat chain conveyors for in and out feed of building elements.
The station is motor driven collaterally in order to be able to put the floor component in a center position into the buffer position 40.

Position 40     Buffer stacker for floor component
Max. Weight 1500 kg
Max. Weight on stacker 7 500 kg

The stacker is designed to stack floor components on top of each other. The floor components are transported into the stacker on rollers. The rollers are placed with the outer dimension of 3000 mm. Between the rollers is a lifting table, the table has arms that are placed between the tables.

Lifting table 7500 kg dimensions 5000 x 1500 mm.
On both sides of the rollers is a gantry with 3 pneumatically movable arms, width 300 mm. On both sides of the station are the arms manually movable 750 mm. C-C arms lengthwise 3,2 m.

Functional description
The operator places the beams approx. 200 mm, the building elements are stacked with a distance of approx. 200 mm.

When a building element is stacked the lifting table lifts the building element until it reaches the prior stacked building element and lifts it in order for the arms to be lowered. When the arms have been lowered the lifting table continues to lift the floor element until it reaches a level above the arms and the arms can go back beneath the new floor element. The lifting table is lowered once more and the stack with floor elements rests on the arms. The described stacking process is repeated until max. lifting capacity of 7500 kg is reached.

 
Volumetric mounting line

Position 41       Wagon for transport of floor element to volumetric mounting line
The station consists of 3 wagons with roller rails; the wagons are connected with bars and have the same distance as the rails in the volumetric mounting line. The roller rails are equipped with fixed stoppers on one side that the floor element can be positioned against when loading the elements.

Position 42       Wagon for transport of complete volumes
Wagon with 3 rail rollers. The rail rollers are equipped with fixed stoppers on one side. The wagon is motor driven collaterally with manual control, transport distance approx. 100 m.
Position 43      Working platform 11 m line
Technical Description
The design consists of 4 platforms. Beneath each platform 6 lifting devices are installed. The lift of stroke is set up so the platforms in a upraised position is over the rail rollers (image 1 and 2). On the platforms it is possible to shims 40, 60 and 105 mm be placed. The placement of shims enables a correct distance from the lower edge of the wall. When the platforms are in the bottom position they are placed beneath the rail rollers (110 mm) enabling the biggest shim to be put beneath the rail rollers (image 3 and 4).

Functional description

•    The shims are placed on the platforms when these are in a lower position
•    The platforms are in lower position when the floor element in rolled in from position 31
•    The lifting device is raised to a level where the platforms reached above the rail rollers. The chosen shim gives the distance between wall and floor
•    The first long side wall element is placed against the stoppers at the platform and support device from roof is lowered. The wall is fixed.
•    The other long side wall is placed and mounted on a similar way. Pneumatically cylinders fixate the wall against the floor element.
•    The walls are screwed to the floor element.
•    When both long side walls are mounted one of the short side walls are mounted. Stoppers on top and bottom of the long side wall guarantees correct placement and angles of the short side wall.
•    The inner walls are mounted and the second short side wall.
•    When the roof is mounted the walls are slightly leaned out from the volumetric building component in order to simplify the mounting.
•    The lifting devices are emptied of air and lowered giving them a level lower than the rail rollers. The volumetric building component can hereby easily be transported.

 
Image 1: Lifting device in upraise position

 
Image 2: Lifting device in upraise position

 
Image 3: Lifting device in lower position

 
Image 4: Lifting device in lower position

 
Image 5: The floor element is rolled over

 
Image 6: Lifting devices are raised in order to mount floor and long side wall

 
Image 7: The short side walls are mounted

    
Position 44      Working platforms 9,5 m line, quantity 2
Same as position 42 with platforms adjusted for 9,5 m volumetric building components.

Position 45     Volumetric tracks
3 mounting tracks length 74 m, every track has 3 rail rollers, in total 666 m.

 
Roof Production Line
                
Position 50     Working Station WT 2000-108
The station has 2 driven flat chain conveyors for in and out feed of building elements.
One chain is on the adjustable side that is motor driven for width adjustment of the station.

Position 51     Working Station WT 2000-108
The station has 2 driven flat chain conveyors for in and out feed of building elements.
One chain is on the adjustable side that is motor driven for width adjustment of the station.

Position 52     Working Station WT 2000-108
The station has 2 driven flat chain conveyors for in and out feed of building elements.
One chain is on the adjustable side that is motor driven for width adjustment of the station.

Position 53     Working Station WT 2000-108 with angle transfer
The station has 2 driven flat chain conveyors for in and out feed of building elements.
One chain is on the adjustable side that is motor driven for width adjustment of the station.
The station is equipped with cross mounted rollers for transport of building element to the roof buffer station.

Position 54     Buffer stacker for roof elements
Max. Weight 1500 kg
Max. Weight on stacker 7 500 kg

The stacker is designed to stack roof elements on top of each other. The roof elements are transported into the stacker on rollers. The rollers are placed with the outer dimension of 3000 mm. Between the rollers is a lifting table, the table has arms that are placed between the tables. The in feed of the roof elements is done from the side.

Lifting table 7500 kg, dimensions 5000 x 1500 mm.
On both sides of the rollers is a gantry with 3 pneumatically movable arms, width 300 mm. On both sides of the station are the arms manually movable 750 mm. C-C arms lengthwise 3,2 m.

Functional description
The operator places the beams approx. 200 mm, the building elements are stacked with a distance of approx. 200 mm.

When a building element is stacked the lifting table lifts the building element until the it reached the prior stacked building element and lifts it in order for the arms to be lowered. When the arms have been lowered the lifting table continues to lift the floor element until it reaches a level above the arms and the arms can go back beneath the new roof element. The lifting table is lowered once more and the stack with roof elements rests on the arms. The described stacking process is repeated until max. lifting capacity of 7500 kg is reached.


Position 60     Butterfly Table BS 20-6m
Working table with hydraulic turning function that consists of a upraiser table and receiver table. The upraiser table has a pneumatic squaring function and manual width adjustment from 2250 to 3200 mm.

Position 61     Overhead crane for sheet handling, quantity 2
The vacuum lift is mounted on existing roof construction and placed at position 31 and 36. Working area 12 x 6