Abstract: Automated systems and methods of manufacturing truss elements for use in modular construction units can include stations, or steps, for forming angled webs, upright webs, and truss chords for use in the truss elements, transferring such angled webs, upright webs, and truss chords onto an assembly jig in a configuration corresponding to the truss element being manufactured, rigidly interconnecting, via nail plates, the angled webs, the upright webs, and the truss chords to form a finished truss element, and unloading the finished truss element from the assembly jig.

Abstract: An insulation installation system and method of installing insulation in a wall structure for a modular construction unit. The insulation installation system includes an insulation in-feed table, an insulation out-feed table, an insulation saw assembly, and an insulation unload tool. The insulation in-feed table moves a batt of insulation thereon. The insulation out-feed table receives the batt of insulation from the insulation in-feed table. The insulation saw assembly includes an insulation saw that cuts the batt of insulation into a cut insulation having a size to fit into a wall cavity of the wall structure. The insulation unload tool grabs the cut insulation from the insulation out-feed table and places the cut insulation into the wall cavity of the wall structure.

Abstract: A connector system for interconnecting vertically adjacent and/or laterally adjacent modular units of a building constructed from such modular units assembled rigidly together includes connectors that are rigidly attached to the modular units. These connectors are able to rigidly interlock with each other so that, when the connectors of adjacent modular units are interlocked with each other, the adjacent modular units are also rigidly attached to each other. The connectors include sliding alignment features that ensure that resist lateral displacement of laterally adjacent modular units and also ensure proper alignment of vertically-engaging retention features that resist vertical displacement of vertically adjacent modular units.

Abstract: A nail gun for repeatedly driving nails into a substrate includes a drive assembly having a longitudinal axis, a feed head assembly attached to the drive assembly and configured to provide the nails to an output segment, a hammer configured to reciprocate along the longitudinal axis of the drive assembly to drive the nails into the substrate, and a reservoir assembly configured to provide compressed air to the drive assembly to reciprocate the hammer and drive the nail into the substrate. A method drives nails into a substrate with the nail gun.

Abstract: A modular elevator system has a pit module, one or more shaft modules that are attachable to the pit module and/or to an adjacent shaft module, and a cap module that is attachable to an uppermost shaft module. The pit module, the shaft modules, and the cap module are each pre-fabricated and transported to a site at which a building is under construction for assembly top of the pit module, the remaining shaft modules are secured sequentially on top of each other, and the cap module is secured on top of the uppermost shaft module.

Abstract: A system and method for assembling framing assemblies for use as ceiling or floor structures of modular building units using automation are disclosed. The framing assemblies include trusses that are attached at the lateral edges thereof by a joist including at least one layer of dimensional lumber to form a substantially rigid framework. Cover panels are positioned over and attached to an inner surface of the framing assembly.

Abstract: 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.

Abstract: A system and method for assembling framing assemblies for use as ceiling or floor structures of modular building units using automation are disclosed. The framing assemblies include trusses that are attached at the lateral edges thereof by a joist including at least one layer of dimensional lumber to form a substantially rigid framework. Cover panels are positioned over and attached to an inner surface of the framing assembly.

Abstract: 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.

Abstract: A system and method for assembling framing assemblies for use as ceiling or floor structures of modular building units using automation are disclosed. The framing assemblies include trusses that are attached at the lateral edges thereof by a joist including at least one layer of dimensional lumber to form a substantially rigid framework. Cover panels are positioned over and attached to an inner surface of the framing assembly.