U.S. patent application number 11/492703 was filed with the patent office on 2007-02-08 for apparatus and methods for double ended processing.
Invention is credited to David Lee, David A. Morgan, Philip P. Sawyer.
Application Number | 20070028730 11/492703 |
Document ID | / |
Family ID | 37716433 |
Filed Date | 2007-02-08 |
United States Patent
Application |
20070028730 |
Kind Code |
A1 |
Sawyer; Philip P. ; et
al. |
February 8, 2007 |
Apparatus and methods for double ended processing
Abstract
System, including apparatus and method, involves processing
materials in opposite directions between two machines along a
processing path.
Inventors: |
Sawyer; Philip P.;
(Portland, OR) ; Morgan; David A.; (Portland,
OR) ; Lee; David; (Vancouver, WA) |
Correspondence
Address: |
KOLISCH HARTWELL, P.C.
200 PACIFIC BUILDING
520 SW YAMHILL STREET
PORTLAND
OR
97204
US
|
Family ID: |
37716433 |
Appl. No.: |
11/492703 |
Filed: |
July 24, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10645832 |
Aug 20, 2003 |
7080431 |
|
|
11492703 |
Jul 24, 2006 |
|
|
|
Current U.S.
Class: |
83/13 ; 83/73;
83/75.5 |
Current CPC
Class: |
Y10T 83/04 20150401;
B23D 59/008 20130101; Y10T 83/145 20150401; Y10T 83/155 20150401;
Y10T 83/2033 20150401; B27M 1/08 20130101; B23D 59/001
20130101 |
Class at
Publication: |
083/013 ;
083/073; 083/075.5 |
International
Class: |
B26D 1/00 20060101
B26D001/00 |
Claims
1. A method of cutting material comprising connecting a computer to
a saw machine, the computer being programmed to optimize cutting of
stock to satisfy a cut list, measuring a piece of material to be
cut, marking defects in the piece of material by signaling location
of the defect without affixing an actual mark on the piece of
material, automatically calculating a plan for optimal cutting of
the piece of material to fulfill cut list requirements, executing
the plan including automatically pushing the piece of material
toward the saw, and cutting the piece of material according to the
plan into one or more cut list part, and automatically printing
labels for the cut list parts, each label indicating information
about the part.
2. The method of claim 1 wherein the marking step includes the step
of deflecting a light beam at a location near a defect in the piece
of material.
3. The method of claim 1 further comprising activating a visible
signal in relation to the marking step, informing a user of a
feature location.
4. The method of claim 1 wherein the marking step includes the
steps of positioning an object proximally and distally relative to
a defect.
5. The method of claim 4 wherein the marling step is carried out by
a marking system including an object for marking location of
defects, the object being slidable along a track parallel to the
direction of material processing.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation application of Ser. No. 10/645,832
filed Aug. 20, 2003 which will issue as U.S. Pat. No. 7,080,431 on
Jul. 25, 2006 which is hereby incorporated by reference in its
entirety.
[0002] This application incorporates by reference in its entirety
the following U.S. patent applications and patents: U.S. patent
application Ser. No. 09/578,806 filed May 24, 2000 entitled
"Automated Fence Control Coupling System"; U.S. patent application
Ser. No. 09/861,231 filed May 17, 2001 entitled "System and Method
of Marking Materials for Automated Processing"; U.S. patent
application Ser. No. 10/104,492 filed Mar. 22, 2002 entitled
"Automated Fence Control Coupling System"; U.S. Provisional Patent
Application Ser. No. 60/405,068 filed Aug. 20, 2002 entitled
"Process Management System and Method"; and U.S. Pat. Nos. 491,307;
2,315,458; 2,731,989; 2,740,437; 2,852,049; 3,994,484; 4,111,088;
4,434,693; 4,658,687; 4,791,757; 4,805,505; 4,901,992; 5,251,142;
5,443,554; 5,444,635; 5,460,070; 5,524,514; and 6,216,574.
FIELD OF THE INVENTION
[0003] The invention relates to material processing, particularly
involving an automated pusher device operatively positioned between
two machines along a processing path.
BACKGROUND OF THE INVENTION
[0004] Automated saws are used extensively to cut materials for
many different manufacturing applications. For example, saws may
use a microprocessor to determine how to cut according to a
user-supplied list of required dimensions, i.e., a cut list. The
microprocessor controls movement of a fence to position sites of
cutting in a manner that optimizes utilization of raw material. For
some applications, the operator may need to mark defects, such as
knots, cracks, or discolored portions of a material, before
cutting. The marked locations of defects allow the microprocessor
to select cutting sites that exclude defects while making optimal
use of the material according to the cut list requirements.
[0005] Manufacturing operations often have multiple machines which
may be advantageously coupled to an automated positioner. However,
buying separate positioning assemblies for multiple machines may
not be cost effective, or may take up too much space.
Alternatively, a positioning device may be disconnected from one
machine and reconnected to another machine. However, this may be
too time consuming.
SUMMARY OF THE INVENTION
[0006] The invention includes numerous aspects and permutations. In
a preferred example a linear processing path is defined along a
table structure. A first machine such as a saw is positioned along
the processing path. A second machine is positioned along the
processing path. A pusher is positioned along the processing path
between the first and second machines. The pusher is operable to
feed materials, alternately, toward the first and second
machines.
[0007] In another aspect of the invention a method is carried out.
An apparatus includes a pusher positioned between first and second
machines along a processing path. The pusher is operable to push
work pieces alternately in opposite directions toward both
machines. The pusher is controlled by a computer. An interlock is
provided for each machine to prevent operation of the respective
machine when the pusher is moving. A machine is first selected for
use. The interlock for the machine is activated. A work piece such
a piece of lumber is placed on the processing path between the
pusher and the selected machine. The pusher is driven to push the
work piece a calculated distance toward the selected machine. The
pusher stops at an appropriate point. The interlock is disengaged,
thereby re-enabling the machine to operate on the work piece.
Alteration of the work piece is carried out by the machine. The
alteration event is acknowledged by the computer. The interlock is
re-engaged so the pusher can move to the next appropriate point
along the processing path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a view of an automated processing system including
a virtual marking assembly, in accordance with aspects of the
invention.
[0009] FIG. 2 is a schematic side elevation view of the virtual
marking assembly of FIG. 1 showing a default optical path.
[0010] FIG. 3 is a schematic side elevation view of the marking
assembly of FIG. 2 with an object marking a proximal boundary of a
feature location by creating a new optical path.
[0011] FIG. 4 is a schematic side elevation view of the marking
assembly of FIG. 2 with an object marking a distal boundary of a
feature location by creating a new optical path.
[0012] FIG. 5 is a schematic side elevation view of a marking
system according to another embodiment of the invention.
[0013] FIG. 6 is a schematic view of a marking system according to
yet another embodiment of the invention.
[0014] FIG. 7 is a schematic view of an automated material
processing system, in accordance with an embodiment of the
invention.
[0015] FIG. 8 shows a flow chart illustrating a method of salvaging
material.
[0016] FIGS. 9 and 10 show side views manufacturing assemblies
configured for double ended processing.
DETAILED DESCRIPTION OF EXAMPLES OF THE INVENTION
[0017] An example of an automated processing system constructed in
accordance with the present invention is shown generally at 10 in
FIG. 1. System 10 includes a marking assembly 12 positioned along a
front portion of the system. Marking assembly 12 includes a marking
station 14 to orient an article or material 16 relative to an
optical measuring device 18. The article may be a wood product,
metal, plastic, ceramic, and/or the like. The article may have any
suitable shape and size, and may be elongate to define a long axis,
which also may be a processing axis.
[0018] Feature locations 20 along a processing axis 22 of material
16 may be input by a user to the optical measuring device 18, which
communicates the feature locations to a controller 24. Another
computer 24a may be used remotely from controller 24 to store,
edit, combine, or modify cut lists prior to downloading one or more
cut lists to controller 24. Marking assembly 12 allows a user to
virtually mark feature locations 20 of material 16 along processing
axis 22 of the material. A "virtual mark" means a noted location on
a material relative to a registration point such as an end of the
material or an axis, without requiring an actual physical mark on
the material.
[0019] Optical measuring device 18 may provide data input for
processing. The optical measuring device may send a light beam
along optical path 26. As described in more detail below, this path
may be altered for at least a portion of the light beam by placing
an object into the light beam at a location corresponding to a
perimeter region of feature location 20. Alternatively, the object
may be placed at a selected location that inputs data about other
structural aspects of the material or about nonstructural aspects
of material processing. Controller 24 may use one or more
structural aspects of the material, such as feature locations 20
and/or overall length, among others, to determine cutting sites.
Structural aspects may include dimensions, defect locations, grade
of material, etc. One or more structural aspects may be input
optically and/or with another user interface.
[0020] Processing station 28 may be configured to process the
material automatically based on the optically input data. Material
processing, as used herein, may include any structural alteration
of an article (a material). The structural alteration may include
removing or separating a portion of the article (such as by
cutting, boring, punching, routing, mortising, sanding, drilling,
shearing, etc.), adding another component (such as a fastener, a
colorant, a sealing agent, a connected component, etc.), forming a
joint (such as by tenoning), reshaping the article (such as by
stamping, compression, bending, etc.), and/or altering the strength
of the article (such as by heating, electromagnetic radiation
exposure, radiation treatment, etc.), among others.
[0021] Station 28 may include a positioner assembly 29, which may
position previously-marked material 30, relative to a material
processing device, such as a saw 32. Positioned material 30 may be
processed at one or more discrete positions along processing axis
34 of material 30 by saw 32. Material processing may be based on
virtually-marked feature locations 20 or other processing data
supplied by the user, by deflecting a light beam, as described
below. Material processing also may be in accordance with a
processing list, such as a cut list, which may be stored in or
otherwise accessible to controller 24.
[0022] In some embodiments, a material feeding or positioning
device 37, such as a roll feeder, may be used to feed material to a
material processing device, such as a saw, in processing station
28. Alternatively, a pusher mechanism may be employed to engage an
end of the material and push the material relative to the
processing station, particularly relative to a material processing
device of the processing station. Movement of a material
positioning device (and/or a material processing device) along a
line defines a processing line for in-line processing of an
article. Accordingly, an article may be processed at one position
or a plurality of discrete positions arrayed parallel to the
processing line.
[0023] As shown schematically in FIG. 2, optical measuring device
18 includes a light source 42 and a light detector 44. Light source
42 sends or transmits a light beam 46, produced, for example, by a
continuous or pulsed laser, along default optical path 26 to
reflector 48, which reflects the light beam back to detector 44.
Reflector 48 is an optional component of marking station 12 that
provides a default optical path when the user has not interrupted
optical path 26. Reflector 48 may be useful for calibrating optical
measuring device 18 and to assist in positioning and measuring
material 16, as described more fully below.
[0024] Processing data may be created by optical measuring device
18 according to the position at which light beam 46 is deflected
manually. The processing data created may be analog and/or digital
data. Deflection of a light beam, as used herein, is any deviation
produced in at least a portion of the light beam away from a
particular direction of travel, generally along a line. Deflection
of the light beam may be produced by any suitable optical
mechanism, including reflection, refraction, diffraction,
scattering, and/or the like.
[0025] Detector 44 receives light from light beam 46 and detects
any property of the light that allows device 18 to measure the
position at which the light beam was deflected. For example, the
detector may measure the length of optical path 26. In some
embodiments, detector 44 may provide measurement of a
time-of-flight of light from light beam 46 along optical path 26 by
signaling light detection to a clock. The clock may measure the
time-of-flight between light transmission and light detection and
thus may provide a distance measurement or a related light
parameter to be sent to controller 24 through any suitable means
such as communications link 50 of FIG. 1. Rather than a
time-of-flight measurement, any other property of light from light
beam 46 may be measured to determine distance, such as angle of
deflection for triangulation (see FIG. 6), or a phase shift using
an interferometer, among others. Suitable optical measuring devices
for use in the present invention are available from Leica
Geosystems of Herrbrugg, Switzerland, under the name DISTO or from
Hilti Corporation of Tulsa, Okla., under the names PD10 or
PD20.
[0026] As shown in FIGS. 1 and 2, processing axis 22 of material 16
may be positioned substantially parallel to optical path 26, or a
portion thereof, as processing data is input by deflection of the
light beam. The light beam may be sent from light source 42, at a
distance 54 from distal end 56 of wood product 16. Light beam 46
may travel along optical path 26 in a spaced relation from surface
60, for example, about 2 inches above surface 60. As shown in FIG.
2, surface 60 of material 16 may be substantially parallel to
optical path 26, or a data input line thereof, and may be a top
surface or a side surface of material 16. Optical path 26 also may
be disposed below a bottom surface of material 16 and visualized
with an appropriately-positioned mirror or mirrors.
[0027] The long axis and/or processing axis of material 16 may be
oriented at least substantially parallel to optical path 26 in
marking station 14, using an appropriate supporting structure such
as brackets 64. Reflector 48 may act to define the default optical
path 26. A proximal end 66 of material 16 may abut reflector 48.
Proximal end 66 may be marked optically by deflection of the light
beam by reflector 48, or may be manually marked by altering optical
path 26, as described below, without the use of reflector 48.
[0028] FIGS. 3-4 show schematically how optical path 26, for at
least a portion of the light beam, may be altered by an object
marking feature locations 20 of feature 68 in material 16. Feature
68 may be any aspect of material 16 between proximal end 66 and
distal end 56 that may affect processing of material 16. For
example, when material 16 is a wood product, a feature 68 may be a
defect such as a knot, crack, recess, discolored portion, or uneven
surface aberration. Features also may include proximal end 66 and
distal end 56 of material 16. In some cases, a feature 68 may
include any structural aspect of material 16 that influences
subsequent processing of the material. With a wood product as
material 16, feature location 20 typically defines a beginning or
boundary location of a clear portion of the wood product that is
defect-free.
[0029] As shown in FIG. 3, proximal end 69 of defect 68 may be
marked by manually placing an object 70 in the light beam. The term
manual, as used herein, means employing human rather than
mechanical energy, that is, not automatic. Accordingly, object 70
may be any user-controlled object capable of deflecting some or all
of light beam 46 to detector 44 from a position within optical path
26. Since many objects can deflect light, the choices for object 70
are numerous. For example, object 70 may be provided by a portion
of the operator's body, such as a hand, a finger, an arm, a leg, a
foot, a shoulder, etc. Alternatively, the object may be distinct
from the operator, such as a pen, pointer, paddle, mirror, or the
like. Such a distinct object may be grasped by an operator,
connected to any suitable portion of the operator's body, or may be
coupled to the marking assembly. In some embodiments, object 70 may
be slidable along a track that extends parallel to the light beam,
and may be manually placed in the light beam while coupled to the
track.
[0030] In the example of FIG. 3, object 70 is positioned above the
proximal end 69 of defect 68, at a feature location 20 slightly
proximal to defect 68. Interrupted, shortened optical path 74 is
measured by detector 44 and communicated to controller 24.
Similarly, distal end 80 of defect 68 may be marked by positioning
object 70, as shown in FIG. 4, at a point along a default optical
path 26 corresponding to distal end 80, to produce shortened
optical path 78.
[0031] A feature location corresponding to distal end 56 of wood
product 16 may be marked with object 70, as previously described,
or by temporarily lowering optical measuring device 18, or by
slightly lifting distal end 56 of material 16 above bracket 64 so
that material 16 alters optical path 26. The feature location at
distal end 56 also may be communicated to controller 24 through
keypad 86 (see FIG. 1) by inputting a total overall value the
dimension of the material as measured along processing axis 22.
[0032] Each optical path 26, 74, 78 may include an angle of
reflection .theta. at which light beam 46 is reflected back to
detector 44. In some embodiments, a maximum angle of reflection
.theta. at each feature location may be less than about 30.degree.,
less than about 20.degree., or less than about 10.degree..
[0033] A typical session for marking material 16 may be initiated
with a signal to controller 24 that the user has material 16
properly positioned on brackets 64. The signal may be initiated by
an input either through keypad 86, a switch, such as foot pedal 88,
or by deflecting light beam 46, among others. Controller 24 then
may recognize and interpret data sent by optical measuring device
18 according to any suitable logical sequence. For example, the
user may use object 70 to mark proximal end 66 and distal end 56 of
material 16 first, followed by internal feature locations 20 of one
or more defects 68. Alternatively, the user may mark all features
20 in linear order, including one or both end positions of material
16. Controller 24 then interprets internal feature locations 20 as
flanking a defect 68. Marking station 12 also may include an
audible and/or visible signal mechanism, such as a bell, buzzer, or
light, that informs the user when a feature location along
processing dimension 22 has been measured and sent to controller
24. For example, light post 89 may be provided to give visible
signals corresponding to data input events such as material
marking, based on light beam deflection.
[0034] Once all feature locations 20 have been communicated to
controller 24, the user may move second material 16 to processing
station 28, for example, after processing of previously processed
first material 30 (see FIG. 1). Alternatively, a processing station
may be located linearly downstream from marking station 14, so that
second material 16 may be moved parallel to its processing axis to
place the second material in the processing station 28. After
second material 16 is moved from the marking station 14, or while
it is still in the marking station, the controller may be signaled
that a third material is to be marked. The third material may be
placed in the marking station and marked by light beam deflection.
Processing of first material 30 and marking of second material 16
may be controlled concurrently by controller 24, for example, by
signaling the controller with foot switch 88. This signal may
activate both positioner assembly 29 and optical marking device 18.
Alternatively, marking assembly 12 may be disposed such that
material 16 may be marked and processed without moving the material
to a distinct processing station.
[0035] In the system shown in FIG. 1, positioner assembly 29 uses
positioner 106 to push first material 30 along processing line 108.
Positioner 106 is any structure that determines the position of
material 30 along processing line 108. Examples of positioner 106
include a pusher, a fence, or a stop block or any other similar
structure configured to move or index material. Typically, the user
places material 30 in processing station 28, on infeed table 110,
so that processing axis 34 of material 30 is parallel with
processing line 108 of positioner 106, by abutment with guide rail
112. Positioner 106 moves parallel to processing line 108 to
contact distal end 114 of wood product 30. Positioner 106 positions
proximal end 116 of wood product 30 an appropriate distance beyond
saw 32 based on a positioning signal sent from controller 24 to a
motor in housing 118. The motor controls movement of positioner 106
through slider 120 in positioner assembly 29. Slider 120 is
displaced along guide rail 112 in response to controller 24
instructions to the motor. Alternatively, instead of a pushing-type
positioner to move material 30 to the saw, the saw may be
automatically moved along the processing line to an appropriate
location for cutting according to marked features. In another
design, a roll feeder may be used to move the material.
[0036] After positioner 106 has automatically positioned wood
product 30 appropriately, saw 32 is activated to process wood
product 30. This may be carried out automatically, for example, by
controller 24 moving saw 32, or manually, by the user moving saw
32. In an alternative configuration, movement of material 30
relative to modifying device 32 may be achieved also by moving
device 32 parallel to processing axis 34, while material 30 is kept
stationary. It should be noted that the marking station 12 may be
useful with any automated processing system in which materials to
be processed include features 68 that vary in location between the
materials along processing axis 22.
[0037] After material 30 is cut, it may continue downstream onto
outfeed table 121. Drop-box hole 121a may be provided in outfeed
table 121 to allow waste pieces to fall into a waste
receptacle.
[0038] FIG. 5 shows a marking system 200 according to an alternate
embodiment of the invention. Light source 202 directs light beam
204 to reflector 206 where the beam is reflected to detector 208.
Bumper 210 maintains material 212, at a fixed location relative to
fixed light beam 204. Portion 214 of light beam 204 between bumper
210 and reflector 206 can be used to create signals by interrupting
beam portion 214. The signals may be interpreted by a computer, for
example, as processing instructions, separate from marking steps on
material 212. This design enables many possible functions and
adaptations to system 200. For example, a virtual keyboard 216 may
be created. A template or similar device may be positioned near
beam portion 214 so that operator may point to or touch different
locations on the template, thereby causing interruptions of beam
204 at different locations. This feature of the invention may be
used to input processing data or instructions that are related to,
or distinct from, structural aspects of the material to be
processed. For example, such data or instructions may signal the
beginning or ending of a structural data input, initiation of
material handling steps, start and/or stop instructions, the grade
of material being processed, processing instructions relative to
marks that have been or will be indicated on the material, etc.
[0039] FIG. 6 shows a marking system 230 that measures distances
based on triangulation. Marking system 230 may be included in any
suitable automated processing system. Marking system 230 may
include an optical measuring device 232 having a light source 202
and a detector 234. The light source may send a beam of light 204
along a data input line 236 to a point of reflection, shown at 238
and 240. The point of reflection may be provided by default
reflector 206 or by an object 70 placed in the light beam at a
selected position along the data input line. Default reflector 206
or object 70 may reflect only a portion of light beam 204 to
detector 234, shown at 242 or 244, such as by diffuse
reflection.
[0040] The angle defined by the reflected light beam may be
measured by detector 234, to provide a measure of the point of
reflection along the data input line. Suitable optics, such as a
lens 246, may be disposed between the point of reflection and the
detector to focus light beam portions 242, 244 onto detector 234.
The position at which each light beam portion is detected by
detector 234 may be used to calculate the point of reflection by
triangulation. For example, light beam portion 242 forms a smaller
angle with data input line 236 than light beam portion 244.
Accordingly, each of these angles may be related to a point of
reflection and thus a distance/position along the data input
line.
[0041] The data input line is any line segment in which an object
may be placed in the light beam to input data for material
processing or system operation to the controller. The data input
line may have any suitable relationship to the light source and
detection mechanism. The data input line may be substantially or
completely formed by air. The data input line may be at least
substantially parallel to the long axis of material 16 and/or
parallel to an axis along which the material is to be processed,
generally at one or more discrete positions. The data input line
may extend from the light source to a default reflector 206.
Alternatively, the data input line may be configured to be a subset
of the line or line segment along which the light beam travels. For
example, positions on this line or segment of travel that are too
close or too far from the light source may not be recognized for
data input. In some embodiments, optical elements, such as lenses
or mirrors may be employed between the light source and the data
input line to direct the light beam along the data input line.
[0042] FIG. 7 shows a schematic view of a system 250 for automated
material processing. System 250 may include a data input station
252, a material processing station 254, and a controller 256, among
others.
[0043] Data input station 252 may be any mechanism for inputting
data to system 250 by manual deflection of a light beam. A
particular position at which the light beam is deflected may input
data that corresponds to the particular position. The data may
relate to operation of the system, processing a material, etc. The
data input station may include an optical measuring device 258 that
provides a light beam. The data input station also may define a
default optical path 260 followed by the light beam. A portion of
optical path 260 may provide a data input line along which the
light beam travels. The optical measuring device may be configured
so that placement of an object in the light beam at a particular
position along the data input line inputs data to controller
256.
[0044] Material processing station 254 may be any mechanism for
processing a material of interest. Station 254 may include a
positioner 264 and a material processing device 266 that provide
in-line processing along a processing line 268. The positioner may
be configured to move parallel to a processing line 268, so that a
material moves toward the material processing device to select
discrete positions of the material, arrayed parallel to the
processing line, at which the material is processed. Alternatively,
or in addition, the material processing device may be configured to
move to discrete positions of the material arrayed in parallel to
processing line 268.
[0045] The material processing station may have any suitable
spatial relationship to the data input station. For example, these
stations may be overlapping, so that the material can be processed
directly after the data is input. Alternatively, these stations may
be spaced, so that the material is moved to the processing station
after data input. For example, these stations may be at least
substantially parallel, that is, data input line 262 may at least
substantially or completely be parallel to processing line 268. The
data input station may be disposed in front of, or behind, the
material processing station, when viewed from a normal position of
operation by a user. Accordingly, a material may be transferred,
manually or automatically, from the data input station to the
material processing station by movement perpendicular to the data
input line and/or processing line. In some embodiments, the data
input line and the processing line of such stations may be spaced
so that a person's arms can transfer the material from the data
input station to the material processing station while the person's
feet are stationary, or spaced by a distance of less than about
four feet. In some embodiments, the data input and material
processing stations may be arrayed lengthwise, so that the stations
are disposed on the left and right of each other in relation to a
user in a normal position of use. Accordingly, the data input line
and the material processing line may be substantially collinear.
The material processing station may be disposed so that the
material is moved substantially parallel to the data input line to
position the material in the material processing station.
[0046] Controller 256 may be any device configured to manipulate
data. Accordingly, the controller may be a digital processor or
other computing device. The controller may be operatively connected
to optical measuring device 258 and material processing station
254, particularly positioner 266 and/or material processing device
268. Accordingly, the controller may be configured to receive data
input by a user through the optical measuring device. In addition,
the controller may be configured to control operation of the
positioner and/or material processing device, such as their
movement, based on the data.
[0047] Controller 256 may be configured to operate data input and
material processing stations concurrently, that is, during
overlapping time intervals. Controller 256 may send and receive
signals from the stations at slightly different times, but overall
the data input and processing operations on two articles may be
conducted at the same time. Accordingly, the data input station may
input data to the controller about a second article or workpiece,
while the material processing device is processing a first article,
based on data previously input to the data input station. In some
embodiments, the controller may be configured to store input
processing data for two or more articles. The material processing
station may be configured to sequentially process the two or more
articles based on the input processing data.
[0048] System 250 may include a user interface 270 to provide a
mechanism in addition to data input station 252 for inputting data
to controller 256. User interface 270 may include a keypad, a
keyboard, a touchscreen, a touchpad, a mouse, a foot-operated
pedal, a voice recognition system, and/or the like.
[0049] Processing system 250 may be equipped with a printer 272, as
shown in FIGS. 1 and 7. The printer may be operated manually or
automatically depending on the application. The printer may be
configured to print hard copy output related to operation of the
processing system. For example, when the processing system includes
a saw, the controller for the saw may be configured so that yield
data is automatically printed out at the end of executing a cut
list. In some embodiments, the printout may summarize: (1) linear
feet cut, (2) percentage of usable material, (3) percentage of
waste material, and/or (4) total cutting time, among others. In
some embodiments, the printer may be configured to print labels.
The labels may include any suitable printed information or indicia,
such as stop movements, piece counts, cut lengths, materials, part
numbers, job names, and/or other kinds of information. The
information can be printed to labels of various sizes, depending on
the source of the data and parameters in the calibration/menu. The
labels may be configured to be applied manually by a user of the
system, or automatically when the material is processed.
[0050] Many different processing variations of the invention may be
used. For example, the system may be programmed to record marks
sequentially in a single direction, so that if a mark is made in or
behind an area that was already marked, then the computer deletes
all data up to that point allowing for correction and remarking of
the area.
[0051] The system may also be programmed to manage handling of
material not conforming to a cut list.
[0052] FIG. 8 shows a flow chart including steps used to salvage
material. A computer is used in conjunction with an automated saw
system such as one of the ones described above. The computer may be
programmed to optimize cutting of stock material to satisfy a cut
list, and may also be programmed to manage use or disposal of
remainder material.
[0053] Generally, there may be two types of remainder material. One
type is referred to as "salvage". Salvage materials are pieces that
do not satisfy cut list requirements and do not contain marked
defects. For example, if two five foot pieces are cut from an
eleven foot board pursuant to a cut list, the remaining one foot
piece (not required by the cut list) is considered salvage
material. A second type of remainder material is referred to as
"defect". Defect materials are pieces that contain defects such as
knots or blemishes, particularly defects that have been actually or
virtually marked by the operator.
[0054] In the system and method illustrated in FIG. 8, a computer
is programmed to optimize and manage salvage or saving of remainder
material. In system 500, the first step 504 involves inputting one
or more cut lists, a minimum salvage length (Smin), a minimum
defect length (Dmin), and a maximum drop box length (DBmax). Next,
pieces of stock or raw material are processed according to the
following routine.
[0055] In step 506 the length of a piece of material is input into
the computer. The length may be measured and input manually by the
operator. Alternatively, the length may be automatically measured
and entered by positioning one or more sensors along the processing
path. The computer may also be programmed to automatically assume
end-cuts of a predetermined dimension will be made prior to
figuring the best strategy or plan for cutting the material.
[0056] In step 508 the operator marks the location of defects.
Marking may be carried out by actually marking and scanning the
material. Alternatively, the preferred approach is to input
location(s) of defects by "virtually marking" the defects using a
light reflection or interruption technique, for example, such as
the methods described above involving use of a light beam
substantially parallel to the processing path.
[0057] In steps 510 and 512 the computer determines how to cut the
material considering optimum use of material to satisfy the cut
list(s), and how to manage remainder material, i.e., salvage and
defect materials.
[0058] In steps 514 and 516 cut list pieces, salvage pieces having
a length equal to or greater than Smin, defect pieces having a
length equal to or greater than Dmin, and adjacent segments of
salvage and defect pieces having a combined length equal to or
greater than Dmin are cut, labeled, and saved for future use.
[0059] In steps 518 and 520 salvage pieces having a length less
than Smin, and defect pieces having a length less than Dmin, are
cut to lengths equal to or less than DBmax, and discarded. A drop
box may be provided with an opening dimensioned to allow disposal
only of pieces having a length equal to or less than DBmax.
[0060] The controller may also be configured to automatically
measure a piece of material prior to cutting. The saw system is
equipped with one or more length sensors. A piece of material is
placed in the processing line. A pusher shoves the material forward
until it reaches the sensor. The controller calculates the length
of the material according to the known position of the pusher at
the time the sensor detected the end of the material. The
controller then determines how best to cut the material based on
the length determination and any defect information entered by the
operator.
[0061] The invention may also be programmed for double ended
processing. For example, the controller may be programmed to
control processing of material between a saw and a drill press, as
shown in FIGS. 9 and 10. In FIG. 9, automated pusher 600 is set up
on table 601, and configured to push workpieces either in direction
602 towards upcut saw 604, or alternatively, in the direction of
arrow 608 toward drill press 610. In the example shown in FIG. 9,
each machine 604 and 610, has a dedicated controller 612 and 614,
respectively, equipped with a keypad for controlling operation of
pusher 600 when being used with the respective machine. Dedicated
interlock devices 616 and 618 are provided to prevent operation of
the machine when pusher 600 is in motion. FIG. 10 is the same as
FIG. 9 except a single keypad controller in keypad 620 is used
interchangeably with the two machines 604 and 610. Keypad 620 is
shown in position for use with drill press 610. The keypad is also
shown in dashed lines in position 620a where it would be used with
saw 604. When pusher 600 is moving, the respective interlock
disables activation of the tool. When pusher 600 reaches the target
location, then the interlock re-enables the tool to operate and
then counts the stroke against the cut list. The appropriate
interlock may operate depending on which end of the positioner
track is designated as the "zero end".
[0062] In another example of the invention, an automatic back-off
feature is implemented. First, the pusher moves a piece of material
to point A relative to a machine such as a saw. Before cutting the
material, the pusher moves back a preset distance. Cutting is
carried out. Then the pusher returns to point A before pushing the
material to the next position. The back-off step prevents the
pusher from shocking or bumping the material while it is being
processed.
[0063] The specific embodiments disclosed and illustrated herein
should not be considered as limiting the scope of the invention.
Numerous variations are possible without falling outside the scope
of the appended claims. For example, the invention may be
implemented in numerous different machine configurations with
varying levels of automation. The invention may also be used to
process many different kinds of materials including, but not
limited to, wood, wood composites, polymeric materials such as PVC,
polystyrene, polypropylene, polyethylene, fiberglass, textiles,
etc. In addition to cutting, the invention may be used to carry out
other processing steps such as boring, punching, routing,
mortising, sanding, drilling, shearing, bonding, sewing, heating,
UV curing, painting or graphics application, etc. The subject
matter of the invention includes all novel and nonobvious
combinations and subcombinations of the various elements, features,
functions, and/or properties disclosed herein.
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