Abstract:
Disclosed is an apparatus, system, and method for precisely placing holes or attaching sub-components to vertical mullions or other workpieces of various shapes and material compositions. The apparatus, in its basic mode of operation, can accurately locate the positions of holes or groupings of holes to be drilled in the workpiece by means of the calibrated positioning, along the workpiece, of a plurality of fixtures affixed to specially-designed drill guide plates. When used in its advanced mode of operation, the fixtures of the apparatus are re-configured and loaded with a plurality of shear blocks or other connectors, and thereupon an operator, by calibrated placement of the fixtures, may simultaneously pinpoint the required fastening location of the shear blocks and sequentially attach specified fasteners through each shear block, directly onto the workpiece.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application claims the benefit of U.S. Provisional Application No. 61/130,418 filed on May 31, 2008. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     There is no federally sponsored research or development in connection with this inventive concept. 
     NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
     There is no joint research agreement applicable to this inventive concept. 
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     The present invention, among other uses and applications, primarily relates to an improved method and system for precisely connecting components of curtain walls. Curtain walls are typically constructed by the assembly of support members comprising a complete frame for the support of a plurality of panels which, in turn, serve as a substantial part of the exterior of a building. The panels themselves may be of glass, granite, slate, concrete, or other materials. 
     The curtain walls will normally include a horizontal sill member, a horizontal head member, and numerous vertical mullions running between the sill and head members. Panel members are supported by grooved or u-shaped channels within the sill members and the head members. In some manufacturing processes screw splines or other integral mechanisms are fabricated within the interior of the mullion or usually, some portion of a shear block, to facilitate the attachment of horizontal members to the mullion or the attachment of the mullion to a concrete floor slab in a building under construction. 
     A common construction method involves the attachment of components such as shear blocks or clips to appropriate locations on the exterior or interior of vertical mullions. The horizontally-oriented head and sill members are thereafter affixed to the shear blocks, forming joints and support for the panel members. The present invention may be quickly and efficiently used to more precisely locate the drilling points for attachment holes on a vertical mullion or other workpiece. The inventive concept herein is also designed to simultaneously pinpoint the location of the necessary holes and apply the required fasteners through the shear block directly into the mullion. 
     (2) Description of the Related Art 
     Many different techniques and systems have been developed over the past fifty years for the purpose of constructing, assembling, and attaching vertical mullions, sills, head members, and the enclosed panel members to the structure of buildings. U.S. Pat. No. 3,147,518 (Horgan, 1964) was one of the earliest exhibiting the construction of curtain walls utilizing mullions comprised of extruded aluminum. The method disclosed drilling holes into the mullion and afterwards, the insertion of self-tapping screws to unite the mullion with horizontal members. Another consideration involved the factor of insulation and waterproofing, thus caulking was used extensively during construction. 
     As the various designs and means of connecting and securing frame members to each other and to the building structure evolved, the majority of methods were very similar. U.S. Pat. No. 3,961,452 (Hubbard et al, 1976) speaks of a screw spline system. The vertical mullions are drilled with holes in the appropriate places to receive shear pins. The horizontal members were attached by the insertion of the shear pins into screw splines formed in the horizontal member. The heads of the shear pins are then tapped downward until the shear pins bottom in the holes previously drilled in the mullions. 
     A stopless butt-joint multiple curtain wall system was disclosed in U.S. Pat. No. 5,355,645 (Farag, 1994) wherein a grid system is constructed from within a building under construction. One of the claims featured split mullion interlocking halves, each half secured to the other by interconnection of male to female connectors. Clips and retainers were also utilized for panels and receiving mullion, thus for the most part eliminating the need to drill holes. 
     In U.S. Pat. No. 6,158,182 (Biebuyck, 2000), disclosed is a method of assembling a curtain wall in a controlled environment within a factory, thus yielding more precision, higher tolerances, and lower labor costs. Completed sections of curtain wall then are transported to the building site for attaching to the building structure. Each mullion member has extruded splines on its interior surface and an exterior shelf. Sills, heads, and intermediate horizontal members have similar structures which include pressure plates. The pressure plates contain holes which correspond with holes drilled on the exterior shelf of the mullion. The method also emphasizes an efficient means of anchoring curtain walls to a slab or structure. 
     A hollow body hole punching apparatus is disclosed in U.S. Pat. No. 6,561,065 Ranalli, 2003) wherein an “elongated hollow body” or mullion is described as the typical workpiece. An expandable die is inserted into the mullion which rests upon a support table. A positioning bar is connected to the die and manipulates the mullion into alignment with an overhead punch press. The die, which is fabricated with die cavities, is then mechanically expanded, thus preventing collapse of the mullion as the holes are punched. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention, among other uses and applications, relates to an apparatus which makes possible an improved method and system for assembling and anchoring components of curtain walls. The apparatus essentially is an elongated worktable comprised of two parallel and horizontally running support rails. The support rails are attached to a plurality of steel channel legs, with the entire assemblage forming a railed platform. The railed platform further contains, directly behind and parallel to its rearmost rail, a backstop which supports a plurality of pivotable, metallic fixtures. The fixtures are orthogonally attached to the top surface of the backstop at intervals dictated by a construction drawing. The metallic fixtures can function as either jigs or tool guides. 
     Prior to operating the device in its basic drilling mode, a plurality of planar drill plates are machined with patterns and/or groupings of holes corresponding to designated attachment points on a subject workpiece. The drill plates are secured to appropriate fixtures, normally by a threaded attachment means. Once the workpiece is placed horizontally upon the railed platform and secured against the backstop, the fixtures are slidingly positioned and clamped at precise positions, according to scalar measurements on the backstop. Each fixture is then pivotally rotated to horizontally interface with the workpiece. Thereby, an operator may accurately drill the required holes, using the drill plates as a jig, or guide. 
     In the advanced mode of operation the step of drilling holes into the workpiece is eliminated by the utilization of a different type of fixture. These re-configured fixtures are attached to loading plates, which plates are designed to graspingly hold shear blocks. The loading plates are custom-fabricated of such size and contour as to permit a specific shear block to be securely grasped within the inner perimeter of the loading plate. Similar to the basic mode of operation, the fixtures are positioned and clamped at exact positions upon the backstop, and rotated downward, flush with the workpiece. An operator, using manual or overhead automated equipment and the required fasteners, accurately attaches each shear block directly to the mullion at the location of each horizontally-positioned fixture. 
     The reader is advised that, for the sake of convenience and clarity, the operation of this device has been described primarily with vertical mullion as being the subject workpiece. However, the inventive concept is suitable for precise drilling and related operations on a variety of materials and objects of primarily planar dimensions. Therefore, the descriptions rendered herein are not considered to be restrictive or limiting of the operation of the device. 
    
    
     
       BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS 
       A more thorough understanding of the present invention and fabrication system may be had by reference to the drawings herein, of which a brief summation of each drawing follows: 
         FIG. 1  is a view, in perspective, of the basic railed platform, less the tooling, pneumatic cylinders, and moveable fixtures required for operation. 
         FIG. 2  depicts a plan view of a section of the railed platform, in which (a) two pneumatic cylinders and (b) two fixtures attached to empty loading plates are shown. 
         FIG. 3  presents the side elevation view of the calibrating end of the railed platform of  FIG. 2 , further depicting the cross section of a typical workpiece. 
         FIG. 4  illustrates the front interfacing surface of a typical drill plate as attached to the arm of a fixture, along with the hole position locator. 
         FIG. 5  is a side view of the flip-up fixture/drill plate assembly, including a prospective view of the assembly transitioning to its horizontal operating position. 
         FIG. 6  is a perspective view of a flip-up fixture in its vertical disengaged position and further illustrating the attached hole position locator. 
         FIG. 7  is the side view of  FIG. 6 , further depicting an intermediate position of the fixture transitioning to a horizontal engaged position with a workpiece. 
         FIG. 8  illustrates an isometric view of the flip-up fixture/drill plate, the assembly having been rotated upwards to its vertical, disengaged position. 
         FIG. 8(   a ) presents an isometric view, from an operator&#39;s position, of the vertical, disengaged position of the flip-up fixture as it is clamped to the backstop. 
         FIG. 9  depicts a flip-up fixture containing, within its inner perimeter, a shear block. The assembly has been pivoted so as to interface with a workpiece. 
         FIG. 10  is a rendering of a fastener commonly used to attach shear blocks to a vertical mullion. 
         FIG. 11  illustrates one of a plurality of non-mar supports designed to slidingly fit over the front and rear rails of the apparatus while supporting a workpiece. 
       
         
           
                 
               
                 
                 
                 
               
             
                 
                     
                 
                 
                   NUMERICAL INDEX TO  
                 
                 
                   NOMENCLATURE OF APPARATUS PARTS 
                 
                 
                     
                 
               
               
                 
                     
                 
               
            
             
                 
                     
                    1. 
                   Footing 
                 
                 
                     
                    2. 
                   Steel channel leg 
                 
                 
                     
                    3. 
                   Leg extension 
                 
                 
                     
                    4. 
                   Front rail bed 
                 
                 
                     
                    5. 
                   Rear rail bed 
                 
                 
                     
                    6. 
                   Backstop 
                 
                 
                     
                    7. 
                   Backstop mounting bracket 
                 
                 
                     
                    8. 
                   Endstop 
                 
                 
                     
                    9. 
                   Fixed tape measure 
                 
                 
                     
                   10. 
                   Flow control valve 
                 
                 
                     
                   11. 
                   Vertical adjustment slot 
                 
                 
                     
                   11(a) 
                   Vertical adjustment bolt 
                 
                 
                     
                   12. 
                   Pneumatic cylinder mount bracket 
                 
                 
                     
                   13. 
                   Pneumatic cylinder 
                 
                 
                     
                   14. 
                   Pneumatic line 
                 
                 
                     
                   15. 
                   Manual control lever 
                 
                 
                     
                   16. 
                   Cylinder snubber 
                 
                 
                     
                   17. 
                   Non-mar support 
                 
                 
                     
                   17(a) 
                   Support slot 
                 
                 
                     
                   18. 
                   Flip-up fixture/load plate 
                 
                 
                     
                   19. 
                   Fixture mounting base 
                 
                 
                     
                   20. 
                   Fixture arm 
                 
                 
                     
                   21. 
                   Fixture loading plate 
                 
                 
                     
                   22. 
                   Dowel pin 
                 
                 
                     
                   23. 
                   Backstop clamping setscrew 
                 
                 
                     
                   24(a) 
                   Left angle adjustment setscrew 
                 
                 
                     
                   24(b) 
                   Right angle adjustment setscrew 
                 
                 
                     
                   25(a) 
                   Left fore-aft adjustment screw 
                 
                 
                     
                   25(b) 
                   Right fore-aft adjustment screw 
                 
                 
                     
                   26(a) 
                   Top socket-head cap screw 
                 
                 
                     
                   26(b) 
                   Lower socket-head cap screw 
                 
                 
                     
                   27. 
                   Middle socket-headed cap screw 
                 
                 
                     
                   28. 
                   Spring-loaded plunger 
                 
                 
                     
                   29. 
                   Hole position locator 
                 
                 
                     
                   30. 
                   Locator adjusting rod 
                 
                 
                     
                   31. 
                   Leading edge of hole locator 
                 
                 
                     
                   32. 
                   Trailing edge of hole locator 
                 
                 
                     
                   33. 
                   Fixture load 
                 
                 
                     
                   34. 
                   Drill plate 
                 
                 
                     
                   34(a) 
                   Drill plate guide hole 
                 
                 
                     
                   35. 
                   Flip-up fixture/drill plate 
                 
                 
                     
                   36. 
                   Mullion 
                 
                 
                     
                   37. 
                   Workpiece 
                 
                 
                     
                   38. 
                   Shear block 
                 
                 
                     
                   39. 
                   n/a 
                 
                 
                     
                   40. 
                   Railed platform 
                 
                 
                     
                   41. 
                   Open space 
                 
                 
                     
                   42. 
                   Line from compressor 
                 
                 
                     
                   43. 
                   Supply line 
                 
                 
                     
                   44. 
                   Hole/attachment pattern 
                 
                 
                     
                   45. 
                   Reference baseline 
                 
                 
                     
                   46. 
                   Calibrating mark 
                 
                 
                     
                   47. 
                   Threaded fastener 
                 
                 
                     
                     
                 
               
            
           
         
       
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In referring first to  FIG. 1 , the railed platform  40  constitutes the basic structure of the apparatus. The front rail bed  4  and rear rail bed  5  are arranged parallel to each other and are securely bolted to a series of regularly-spaced horizontal leg extensions  3 , which are in turn anchored upon steel channel legs  2  and footings  1 . A continuous linear backstop  6  is arranged just aft of, and parallel to, the rear rail bed  5 . The backstop  6  is permanently attached proximate to the rear end of each leg extension  3  by means of backstop mounting brackets  7 . An L-shaped endstop  8  is welded to the leftmost end of the backstop  6 . The endstop  8  comprises a baseline for longitudinal measurements and is used as a zero reference for all computations for the location of attachments and/or placement of drill holes along the surface of a workpiece  37 .  FIG. 2  further clarifies the positioning of a vertical mullion  36  or workpiece  37  as it is being positioned upon the railed platform  40 . 
     Adhesively attached to the top surface of the backstop  6 , and running its entire length, is a fixed tape measure  9 . To ensure an exact horizontal orientation of the subject workpiece  37 , each of the steel channel legs  2  features a vertical adjustment slot  11  and vertical set bolts  11 ( a ), as is depicted in  FIG. 3 . The vertical adjustment slots  11  serve as a means of compensating for possible unevenness of any floor surface upon which the railed platform  40  may be placed. 
     For the sake of easier visualization, and by no means indicative of any limitations of the apparatus, the descriptions herein of the operation of the apparatus shall be predicated upon a vertical mullion  36  being the subject workpiece  37 . 
     Again referring to  FIG. 2  there is shown a plurality of non-mar supports  17  which, as shown in  FIG. 3 , are constructed with two slots  17 ( a ) cut into the lower surface. The non-mar supports  17  prevent abrasive damage to the workpiece  36 ,  37  during positioning and operations. The said slots  17 ( a ) allow the non-mar supports  17  to slidingly and snugly fit over the front rail bed  4  and rear rail bed  5 . A further view of the non-mar support  17  is also shown in  FIG. 11 . 
     The mullion  36 , while subject to operational functions performed thereon, rests on the non-mar supports  17  along the length of the railed platform. The rail beds  4 ,  5  display open space  41  between their parallel runnings, such open spacing  41  permitting axial rotation of the mullion  36  upon the non-mar supports  17  in the course of attaching components. Thusly, there is allowed bottomward clearance for the firstly-attached components while the opposite surface of the mullion  36  is being worked upon. 
     In  FIG. 2  and  FIG. 3 , there appears a box-like structure as symbolic representation of a pneumatic flow control valve  10 , said flow control valve  10  functioning in essence as any of a number of such valves currently in use. A compressor  42  supplies pressurized air, via a supply line  43 , to the flow control valve  10 . Upon the opening of a manual control lever  15 , the pressurized air is ported through pneumatic lines  14  to a plurality of pneumatic cylinders  13 . A pneumatic cylinder  13  is mounted, by means of a pneumatic cylinder mount bracket  12 , upon the top front surface of each leg extension  3 . Referring to  FIG. 3 , once a workpiece  37  is placed into position on the non-mar supports  17 , the pneumatic cylinders  13  are pressurized, thereby forcing the cylinder snubber  16  securely against the workpiece  37 . 
     Basic Mode of Operation 
     The basic working mode of the apparatus consists of pinpointing the precise location and arrangement of holes to be drilled into a vertical mullion  36  or workpiece  37 , in conjunction with the operation of automated or hand-held drill equipment to drill the holes. Assuming, for illustrative purposes, that the workpiece  37  is a vertical mullion  36 , detailed shop drawings are first consulted to determine the pattern, number, dimensions, and location of holes required for the attachment of horizontal members at more or less regular intervals along the length of the mullion  36 . For each intervallic location along the length of the mullion  36 , one or more drill guides, or drill plates  34 , as shown in  FIG. 4  and  FIG. 5 , are then fabricated. Each drill plate  34  is itself through-drilled with the prescribed number and pattern of holes  34 ( a ) corresponding to the hole/attachment pattern  44  of a corresponding intervallic location. Each said intervallic location comprises a concise area wherein a horizontal structural member will be attached to the vertical mullion  36 .  FIG. 2  displays a hole/attachment pattern  44  as it would appear after having been drilled into a workpiece  37 . 
     The drill plates  34  are composed of hardened steel to withstand the heat of the drill mechanism and to minimize gouging of the rim of the drill hole guides  34 ( a ) which may possibly be caused by repetitive drilling operations. The drill plates  34  are further fabricated with a lengthwise dimension commensurate with the length of the fixture arm  20 , facilitating the attachment of the drill plate  34 , by means of socket-headed cap screws  26 ( a ), ( b ) to a fixture arm  20 , as shown in  FIG. 4 . Each drill plate  34 , having been drilled to match the attachment points at a particular intervallic location and attached to a fixture arm  20 , forms a flip-up fixture/drill plate  35 . 
     By referring to  FIG. 2 , a description of the necessary drilling operations begins with the mullion  36  being placed upon the non-mar supports  17 , parallel to the rear rail bed  5 . In  FIG. 3 , the mullion  36  has been pressed firmly against the endstop  8  and the backstop  6  of the railed platform. An operator then moves the control lever  15  toward the open position, allowing pressurized air from the compressor  41  to enter all pneumatic lines  14 . As the pneumatic pressure increases, the pneumatic cylinders  13  are displaced inward toward the lateral surface of the mullion  36 . The pneumatic cylinder snubbers  16  make contact against the surface of the mullion  36 , in effect, causing the entire length of the opposite surface of the mullion  36  to be secured against the backstop  6 . 
     Each flip-up fixture/drill plate  35  is thereupon placed at a first position upon the backstop  6  approximating the specified location of the hole/attachment pattern  44  in the vertical mullion  36 .  FIG. 8  depicts the placement of a flip-up fixture/drill plate  35  at its first approximate position on the backstop  6 . The exact location of each drill plate  34  along the length of the mullion  36  is set by aligning the hole position locator  29  attached to the base  19  of the flip-up fixture/drill plate by referencing the fixed tape measure  9 . The final positioning and clamping of each flip-up fixture/drill plate  35  is accomplished on the backstop  6  by adjustment of the left and right angle adjustment setscrews  24 ( a ) and  24 ( b ) and the left and right fore-aft adjustment screws  25 ( a ),  25 ( b ). 
     The flip-up fixture/drill plate  35  is then rotated downward toward its engaged position, that is laying in a horizontal position, parallel to and proximate to, a workpiece  37 . As a means of similarity and comparison,  FIG. 3  depicts a typical flip-up fixture  18  of the type utilized in conjunction with the invention, in its engaged position; that is, pivoted downward into a horizontal posture and almost flush with the surface of the mullion  36 . At this point, an operator utilizes a manual drill or automated overhead drill equipment to drill each hole in accord with the drill plate guide holes  34 ( a ). 
     Advanced Mode of Operation 
     The attachment of horizontal members to a vertical mullion  36  is greatly enhanced by the advanced operating features of this apparatus. The location of the points of attachment of shear blocks  38 , or other horizontal members, and the actual fastening of such components is done more rapidly and with greater precision. Again, it will be assumed, for demonstrative purposes and not as an indication of limitations of the apparatus, that the workpiece  37  is a vertical mullion  36 , and the horizontal members are shear blocks  38 . 
     Firstly, detailed shop drawings are consulted to determine (1) the metal characteristics, dimensions, and profile of each shear block  38 , and (2) the exact location and orientation, along the length of the mullion  36 , of attachment points for each type of shear block  38  used in the curtain wall assembly. 
     This information is used to fabricate one or more fixture loading plates  21 , as illustrated in  FIG. 6  and  FIG. 7 . Each fixture loading plate  21  is precisely machined with the lateral and longitudinal dimensions to interiorly encompass the corresponding perimeter of each particular shear block  38  required to be attached to the vertical mullion  36 . Each fixture loading plate  21  is further fabricated with a longitudinal dimension commensurate with the length of the fixture arm  20  to which the fixture loading plate  21  will be attached. When these two components are attached by means of socket-headed cap screws  26 ( a ), ( b ),  27 , the completed unit will comprise the flip-up fixture assembly  18 , as shown in  FIG. 6  and  FIG. 7 .  FIG. 9  illustrates the manner in which a typical shear block  38  may be loaded into a flip-up fixture  18 . 
     After completion of construction of the required flip-up fixtures  18 , the mullion  36  is then secured to the railed platform in the same manner as in the basic mode of operation. By reference to the applicable construction drawings, precise measurements are obtained, defining the locations of the various attachment points for each type of shear block  38  required to be attached to the mullion  36 . Using these measurements, a reference baseline  45 , in relation to the bottom of the mullion  36  is established at the apparatus endstop  8 , as shown in  FIG. 2 . From the reference baseline  45 , a calibrating mark  46 , as shown in  FIG. 8(   a ) and in  FIG. 9 , is determined at a corresponding point on the fixed tape measure  9 . The calibrating mark  46  represents a specific longitudinal measurement of the point at which the leading edge  31  of the hole position locator  29  must be aligned to precisely place the flip-up fixture  18  and its corresponding shear block  38  directly over the required attachment point on the mullion  36 . These measurements and placement points are illustrated in  FIG. 9 . 
     Each sequential flip-up fixture  18  is thereafter placed at a first position along the backstop  6  approximating the specified location of the attachment point of the shear block  38 .  FIG. 8(   a ) depicts the placement of a flip-up fixture  18  at its first approximate position. The flip-up fixtures  18  are in turn calibrated by setting the leading edge  31  of each respective hole position locator  29  to its corresponding calibrating mark  46 . This calibration will coincide with the mullion  36  attachment point of the shear block  38  with which the flip-up fixture  18  is loaded. 
     The final positioning and clamping of each flip-up fixture  18  is accomplished on the backstop  6 . Each flip-up fixture  18  is next manually pivoted downward into a horizontal posture, proximately flush with the surface of the mullion  36 . 
     As necessary, adjustments are made to ensure an orthogonal, or an angular, orientation of the base  19  of the flip-up fixture  18  relative to the longitudinal dimension of the workpiece, which in turn assures proper orthogonal (or angular) attachment of the shear block  38  to the mullion  36 . The said adjustments are accomplished manually by either clockwise or counter-clockwise rotations of the fore and aft adjustment screws,  25 ( a ), ( b ) depicted in  FIG. 6  and  FIG. 7 . 
     After completion of all adjustments, an operator utilizes a manual drill or automated overhead drill equipment, along with the appropriate threaded fasteners  47  to attach each shear block  38 , in sequence, to the vertical mullion  36 .