Systems and methods of producing components for use in the construction of modular building units
Disclosed herein are various systems, sub-system, and methods for the manufacture of a wall module for using in building a modular construction unit, e.g., for using in building residential homes, commercial offices, educational or service facilities, etc. using a substantially entirely automated modular construction technique. According to the disclosure herein, the resulting wall module includes an internal wall frame including wall studs attached between a top plate and a bottom plate, with, in some embodiment, one or more framing sub-assemblies attached therein to define openings through the wall module. The wall frame has suitable panel members the respective surfaces thereof corresponding to the interior and exterior surfaces of the modular construction unit. The wall frames, when completely assembled, can be transported to be assembled with other constituent components of the modular construction unit to complete the manufacture of the modular construction unit.
1 . A system for assembling a wall structure for a modular construction unit, the system comprising:
a utility installation station configured to allow installation of at least one of a plurality of utilities within the wall structure, the plurality of utilities comprising plumbing and/or electrical facilities, wherein the wall structure includes a wall frame having one or more studs and one or more sheathing panels on the wall frame;
a first flip table configured to rotate the wall structure from a first horizontal position, in which the one or more sheathing panels are facing up, to a vertical position and to transfer the wall structure to the utility installation station;
an insulation installation station configured to apply an insulation material within one or more cavities of the wall structure; and
a second flip table configured to receive the wall structure from the utility installation station and to rotate the wall structure from the vertical position to a second horizontal position, in which the one or more sheathing panels are facing down, the second horizontal position being approximately 180° relative to the first horizontal position, wherein the second flip table is configured to transfer the wall structure to the insulation installation station.
2 . The system of claim 1 , wherein the first flip table is movably mounted on one or more tracks, and the first flip table is configured to move along the one or more tracks to align the wall structure with the utility installation station.
3 . The system of claim 2 , wherein the first flip table comprises a plurality of rollers arranged adjacent an outermost one of the plurality of tracks such that the wall structure is supported on the plurality of tracks in the first horizontal position and is supported on the plurality of rollers in the vertical position.
4 . The system of claim 1 , wherein the first flip table comprises a frame and a plurality of tracks coupled on the frame, and the first flip table is configured to move the wall structure thereon.
5 . The system of claim 1 , wherein the utility installation station includes one or more tracks and one or more rollers on the one or more tracks, and the one or more rollers are configured to receive the wall structure from the first flip table.
6 . The system of claim 1 , wherein the utility installation station includes a frame that supports lateral guides that are configured to engage with the wall structure to guide the wall structure along the utility installation station.
7 . The system of claim 1 , wherein the second flip table is movably mounted on one or more tracks, and the second flip table is configured to move along the one or more tracks to align with the utility installation station to receive the wall structure from the utility installation station and to move along the one or more tracks to transport the wall structure to the insulation installation station.
8 . The system of claim 1 , wherein the second flip table comprises a frame and a plurality of tracks coupled on the frame, and the second flip table is configured to move the wall structure thereon.
9 . The system of claim 8 , wherein the second flip table comprises a plurality of rollers arranged adjacent an outermost one of the plurality of tracks such that the wall structure is supported on the plurality of tracks in the second horizontal position and is supported on the plurality of rollers in the vertical position.
10 . The system of claim 1 , wherein the insulation installation station includes one or more insulation robots having an insulation head that supplies insulation in the one or more cavities.
11 . The system of claim 1 , further comprising an insulation loading station that is configured to supply insulation to the insulation installation station.
12 . The system of claim 11 , wherein the insulation loading station includes one or more insulation hoppers, a conveyor that transports the insulation thereon, and an insulation unloading robot that lifts the insulation from the conveyor and loads the insulation into the one or more insulation hoppers.
13 . The system of claim 12 , wherein the one or more insulation hoppers are configured to add moisture to the insulation and supply the insulation through one or more supply tubes to the insulation installation station.
14 . The system of claim 12 , wherein the insulation loading station includes an insulation loading robot that is configured to load the insulation onto the conveyor.
15 . The system of claim 12 , wherein the insulation unloading robot is configured to remove packaging from the insulation prior to loading the insulation into the one or more hoppers.