Abstract:
An adjustable jig for assembling curved section panels of a dome structure includes a support surface, multiple arm guide members disposed on the support surface and multiple drives independently moving each of the guide members to position the arm guide members along an arc of a desired curvature. Each arm guide member further includes an adjustable bracket positioning horizontal and vertical components of the curved section panels and a gripping device securing these horizontal and vertical components.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This is a continuation in part of application Ser. No. 11/496,299 filed Jul. 31, 2006, in the name of Salah Eldeib, and entitled SYSTEM AND METHOD FOR MODULAR CONSTRUCTION OF A DOME STRUCTURE AND ASSEMBLY COMPONENTS FOR FACILITATING SAME, the entire contents of which are incorporated herein by reference. 
     
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to a jig for assembling dome section panels curved in two dimensions. 
       BACKGROUND OF THE INVENTION 
       [0003]    Dome structures are noted for their strength and stability. They are highly hurricane resistant since they are aerodynamic and earthquake resistant as a result of their ability to distribute and efficiently dissipate the applied stresses. Monolithic dome structures are typically constructed by elaboration of a concrete ring foundation and require that all tools and machinery to be used are brought to the site of construction. A different method of constructing a dome structure involves creating a first circular segment, having a given diameter and height, which is secured to the ground. The circular segment itself is created by connecting a plurality of individual panels which are curved in both their length and height dimension. Circular segments having a successively decreased diameter are subsequently introduced to complete construction of a dome structure. This was disclosed in a previous patent “System and Method for Modular Construction of a Dome Structure and Assembly Components for Facilitating Same.” It necessitates a method for preparing panels curved in two dimensions. 
         [0004]    An assembly jig for assembling and preparing each panel curved in one dimension was disclosed in Canadian Patent CA 1,228,976. The aforementioned teaches an apparatus comprised of a series of parallel ribs which are connected together and can be moved simultaneously to create a curved surface for assembly of a panel. Since all the ribs are connected and move simultaneously as one unit, the apparatus suffers from the limitation that the curved surface can be in the form of a circular arc or an elliptical arc, but not both. A more significant limitation lies in the absence of a means for introducing or accommodating curvature in a second dimension. Thus, there is a need for an assembly jig that can be utilized to prepare panels curved in two dimension. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention addresses the need for a jig that can be employed to assemble a dome section panel that is curved in two dimensions. According to the present invention, an apparatus incorporates an odd number of guide arms that function to guide and secure the positioning of horizontal and vertical components while they are being fastened to form the section panel. In the preferred embodiment of the present invention, each guide arm possesses an arm carriage that houses a lower bracket and an upper bracket for positioning lower and upper plates, respectively, which define the frame of the curved section panel. The apparatus allows vertical components, which impart strength to the curved section, to be positioned between the lower and upper plates, oriented perpendicular to the lower and upper plates and fastened to the lower and upper plates. The brackets can be rotated to accommodate vertical components that are curved in their height (vertical) dimension, which determines the vertical curvature of the section panel. 
         [0006]    In a preferred embodiment of the present invention, each arm carriage is supported by a base carriage. With the exception of the central base carriage, each base carriage can be moved independently along a curved path, such that the guide arms can be arranged, collectively, in the form an arc. This determines the curvature in the length dimension of the section panel. The location of the base carriages is adjusted according to the desired spacing between vertical components of an assembled curved panel and the desired degree of curvature in the length dimension of an assembled curved panel. Since each guide arm can be moved independently, the guide arms collectively provide a method for introducing curvature either in the form of a circular arc or an elliptical arc. Together, these unique features allow a single apparatus to be employed for the assembly of panels that are curved in two dimensions. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a perspective view of an assembled panel curved in two dimensions. 
           [0008]      FIG. 2  is a side view of a vertical component (a “rib”) to be incorporated into the panel. 
           [0009]      FIG. 3   a  is a side view of a rib and  FIG. 3   b  is a side view of a rib with upper frame plate, lower frame plate, and all shoulder plates fastened thereto. 
           [0010]      FIG. 4  is a perspective view of an assembly jig according to a preferred embodiment of the present invention. 
           [0011]      FIG. 5  is a side view of an assembly jig according to a preferred embodiment of the present invention. 
           [0012]      FIG. 6  is a elevation view of a guide arm according to a preferred embodiment of the present invention. 
           [0013]      FIG. 7  is a plan view of the assembly jig according to a preferred embodiment of the present invention. 
           [0014]      FIG. 8   a  is a elevation view of the first step in the process of assembling a curved panel according to a preferred embodiment of the present invention. 
           [0015]      FIG. 8   b  is a elevation view of the second step in the process of assembling a curved panel according to a preferred embodiment of the present invention. 
           [0016]      FIG. 8   c  is a elevation view of the third step in the process of assembling a curved panel according to a preferred embodiment of the present invention. 
           [0017]      FIG. 8   d  is a elevation view of the fourth step in the process of assembling a curved panel according to a preferred embodiment of the present invention. 
           [0018]      FIG. 9  is a perspective view of an assembly jig according to a second embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    The assembly jig according to the present invention is specifically adapted for the assembly of dome section panels curved in two dimensions. In order to understand the present invention, an exemplary assembled panel  20  curved in two dimensions is shown in  FIG. 1 . The curvature in the length dimension of the assembled section panel is indicated by the dashed line. Each assembled panel includes an upper frame plate  22 , a lower frame plate  24 , an upper anterior shoulder plate  26 , an upper posterior shoulder plate  28 , a lower anterior shoulder plate  30  and a lower posterior shoulder plate  32 . The aforementioned plates  22 ,  24 ,  26 ,  28 ,  30  and  32  can be formed from any suitable engineering material, including OSB (oriented strand board) sheets, plywood, particle board, press board, plastic or steel. The length of the aforementioned plates determines the length dimension of the assembled curved section panel  20 . 
         [0020]    The upper  22  and lower  24  frame plates are fastened to vertical components, termed ribs  34 . Ribs  34  can be formed from any suitable engineering material showing suitable strength characteristics. The height of the ribs  34  determines the height of the assembled curved section panel  20 . A typical rib  34  is illustrated in  FIG. 2 . Each end of rib  34  has a portion  36  cut-away on the anterior and posterior face that allows rib  34  to be nestled between anterior and posterior shoulder plates  26 - 32 . The curvature in the height dimension of a rib  34 , which leads to curvature in the height dimension of the assembled curved section panel  20 , is indicated by the dashed line in  FIG. 2 .  FIG. 3   a  illustrates a side view of rib  34  and  FIG. 3   b  illustrates a side view of rib  34  with continuous upper frame plate  22 , continuous lower frame plate  24  and continuous shoulder plates  26 - 32  assembled thereto. 
         [0021]    A preferred embodiment of the assembly jig  40  is illustrated in  FIG. 4 . The assembly jig includes a plurality of guide arms  42  connected to a flat horizontal surface  44 . Guide arms  42  function to position horizontal and vertical components during the assembly of curved section panels  20 . An odd number of guide arms  42  are incorporated into the assembly jig  40 . While a preferred embodiment of the present invention is described as having seven guide arms  42 , it is within the scope of the present invention that the assembly jig may incorporate any suitable odd number of guide arms  42 , specifically, five, seven or nine guide arms. In one of its aspects, the assembly jig  40  has all of its seven guide arms  42  aligned in a row along one of the edges of the horizontal surface  44 , as illustrated in  FIG. 5 . 
         [0022]    With reference to  FIG. 6 , each guide arm  42  includes a base carriage  46  resting on the horizontal surface  44  and an arm carriage  48  extending from and pivotally connected to the base carriage. As shown in  FIG. 7 , base carriage  46  of a central arm  42  is fixed in its position on the horizontal surface  44 . The remaining base carriages  46  are movable along a curved path  50  on the horizontal surface  44 . Independent movement of each base carriage  46  in either direction along its respective path  50  is controlled by a suitable mechanical means such as a worm gear, hydraulic mechanism or pneumatic mechanism. In a preferred embodiment of the present invention, worm gears  52  (shown, for example, in  FIG. 5 ) are operated manually, although it is within the scope of the present invention that this operation is automated. When the assembly jig  40  is viewed from above, a concentric pattern of curved paths  50  is formed, wherein the length and radius of curved paths  50  increases on moving from the central guide arm  42  to the outermost guide arm  42 , on both the right and left side of the central guide arm  42 , as illustrated in  FIG. 7 . The position of each base carriage  46  on its curved path  50  is chosen according to the desired degree of curvature in the length dimension and the desired spacing between ribs  34  of the assembled curved section panel  20 . 
         [0023]    Each arm carriage  48  can be rotated from its upright position, from 0 to 90 degrees, about an axis that lies perpendicular to the length of the arm carriage  48 . This rotation path  54  is depicted in  FIG. 6 . In a preferred embodiment of the present invention, a cylindrical rod  56  connected at one end to the arm carriage  48  is pivotally connected at its other end to a component on the base carriage  46  which bears a grooved bore that can receive a worm gear  58 . Thus, rotation of the worm gear  58  effects rotation of the arm carriage  48 . While the worm gear  56  has been used in the preferred embodiment, any suitable mechanical means for effecting rotation of the arm carriage  48  can alternatively be employed. It is also within the scope of the present invention that rotation of the arm carriages be automated. 
         [0024]    As illustrated in  FIGS. 4 and 8 , each arm carriage  48  includes a lower bracket  60  which is fixed in its position on the arm carriage  48  and serves to position components during assembly of the curved section panel. Each arm carriage  48  further includes an upper bracket  62  located at the terminal end of the arm carriage  48 . It also serves to position components during the assembly of the curved section panel, and its position along the length of the arm carriage  48  can be adjusted to accommodate different heights of ribs  34 . In the preferred embodiment of the present invention, the position of the upper bracket  62  is adjusted by means of a worm gear  64  (shown in  FIG. 64 ), although any suitable mechanical means for effecting movement of the upper bracket  62  along the length of the arm carriage  48  can be employed. Lower bracket  60  and upper bracket  62  can rotate from 0 to 20 degrees and from 0 to 15 degrees, respectively, about an axis that lies perpendicular to the length of the arm carriage  48 . This rotation allows the brackets to accommodate ribs  34  curved in its height (vertical) dimension, indicated by the dashed line in  FIG. 2 . 
         [0025]    Prior to assembling the curved section panel  20 , the height of the upper bracket  62  on every arm carriage  48  is adjusted to match the height of ribs  34  (and, consequently, of plates  20 ) that are to be used in the assembly. The angle of each the lower and upper bracket  60 ,  62  is then adjusted to match the curvature in the height (vertical) dimension of ribs  34 . The angle at which arm carriages  48  lie is set to a predetermined value that facilitates access to both the lower and upper ends of ribs  34  during assembly. With the exception of the central base carriage  48 , each base carriage  48  is moved to a predetermined position on its associated curved path  50 , which will determine the required curvature, in the length dimension, and the required spacing between ribs  34  in the assembled curved section panel. 
         [0026]    With reference to  FIG. 8   a , the process of assembling a curved section panel begins with placement of the lower frame plate  24  along the lower bracket  60  of the arm carriages  48 . The lower frame plate  24  is held in place by a clamp (not shown) positioned on each arm carriage  48 . The upper frame plate  22  is placed in the upper bracket  62  of the arm carriages  48  and held in place by a clamp (not shown) positioned on the arm carriage  48 . The clamps are known in the prior art and are not a feature of novelty in the present invention. The lower posterior shoulder plate  32  is placed in the lower bracket  60  and fastened to the lower frame plate  24 , as shown in  FIG. 8   b . The upper posterior shoulder plate  28  is then placed in the upper bracket  62  and fastened to the upper frame plate  22 . As illustrated in  FIG. 8   c , one rib  34  is placed longitudinally between the lower bracket  60  and upper bracket  62  of each arm carriage  48 , wherein the cut-away portion  36  at the lower and upper end of each rib  34  is fitted with the lower posterior shoulder plate  32  and upper posterior shoulder plate  28 , respectively. In a final step, the lower anterior shoulder plate  30  is place atop the row of ribs  34  within the lower cut-away portion  36  and the upper anterior shoulder plate  26  is placed atop the row of ribs  34  within the upper cut-away portion  36 , as shown in  FIG. 8   d . The lower and upper anterior shoulder plates  30 ,  26  are then fastened to the ribs  34 . The assembled curved section panel  20  is then removed from the assembly jig  40  and the process is repeated to form additional assembled curved section panels. It is also within the scope of the present invention that the assembly and fastening processes be performed through an automated system. 
         [0027]    As shown in  FIG. 9 , a second embodiment of the assembly jig is also designed for the assembly of dome section panels curved in two dimensions. With reference to  FIG. 9 , the second embodiment of the assembly jig  70  includes five guide arms  72  arranged on a semi-circular shaped support surface  74  and spaced equidistantly from each other. Although the second embodiment is illustrated as utilizing five guide arms  72 , any odd number of guide arms can be utilized. Each of the five guide arms  72  includes a platform  76 , a base carriage  78  and an arm carriage  80  pivotally connected to the base carriage  78 . With the exception of the central guide arm  72  (which is centrally secured), platforms  76  can be moved in either direction along a linear path (not shown) on the support surface  74 . Further, each base carriage  78  moves along a linear path (not shown) on its respective platform  76 . In the second embodiment of the present invention, movement of base carriages  78  is effected by means of a worm gear  82 , although any suitable mechanical means can be employed. Since guide arms  72  are arranged in a semi-circular manner by virtue of the shape of the support surface  74 , the assembly jig  70  is predisposed to assemble section panels curved in its length dimension. The location of platforms  76  and base carriages  78  along their respective paths determines the degree of curvature in the length dimension and the spacing between ribs  34  of the assembled curved section panel. 
         [0028]    Each arm carriage  80  includes a lower bracket  84  and an upper bracket  86  for positioning and securing horizontal and vertical components during the assembly of the curved section panel. The distance between the lower and upper brackets  84 ,  86  can be adjusted to accommodate ribs  34  of different height, and brackets  84 ,  86  can be rotated to accommodate ribs  34  that are curved in their height (vertical) dimension, as described in more detail above with respect to the first preferred embodiment of the present invention. Arm carriages  80  can be rotated from an upright position, perpendicular to the plane of the support surface, from 0 to 90 degrees. In the second embodiment of the present invention, the aforementioned movements are effected by means of worm gears  88  and  90 , respectively although any suitable mechanical means can be employed. 
         [0029]    While there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices and methods illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.