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The Process
Layout
All of the wall and floor panels are produced
on extremely high quality casting tables. Sixty (60) large steel
tables travel throughout the manufacturing plant on a sophisticated
series of rollers and computer-automated racking systems. Each steel
table can accommodate a panel that is up to 12 feet in height and
42 feet in length. Often times, several wall or floor panels are
cast on the same table for greater efficiencies. Prior to layout
procedures, each table is stripped of existing panel product, completely
cleaned and then lightly brushed with a release agent in preparation
for new panel production.
The first layout step requires the robot to interface directly
with the CAD drawings for its specific instructions. Individual
panel dimensions (height and length) are marked with paint by the
robot, directly on the steel table. Locations for door and window
openings, as well as the locations of electrical and telecommunications
boxes are also painted by the robot at this time.
Following the painting procedure, the robot shifts gears and quickly
measures and places the magnets and shuttering (edge forms) that
will define the final height and length of the wall or floor panel.
Large magnets-similar in shape to a bar of gold-- are fed on a conveyor
rack into the robotic area. The robot picks these bars off the rack,
two at a time and then places them on the steel table in the specified
location. Various lengths of steel edge forms are also rack stored
in this area. The robot then picks up the appropriate length section
of edge form and places it down over the magnets, which will hold
the edge form in place until panel completion. The robot's work
is now complete on this panel, and the steel table automatically
advances along the rollers to the next station.
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