U.S. patent application number 12/260031 was filed with the patent office on 2009-04-23 for multi-step system for processing workpieces.
This patent application is currently assigned to Precision Automation, Inc.. Invention is credited to Stuart Aldrich, Spencer B. Dick, David Lee, David A. Morgan.
Application Number | 20090105872 12/260031 |
Document ID | / |
Family ID | 38603596 |
Filed Date | 2009-04-23 |
United States Patent
Application |
20090105872 |
Kind Code |
A1 |
Dick; Spencer B. ; et
al. |
April 23, 2009 |
MULTI-STEP SYSTEM FOR PROCESSING WORKPIECES
Abstract
Systems, including method and apparatus, for processing
workpieces driven automatically along a linear path to a plurality
of positions disposed substantially along the linear path. In some
embodiments, a workpiece may be processed at one or more of the
positions using two or more processing stations, such as a first
processing station that cuts the workpiece into segments and a
second processing station that performs another processing
operation on the workpiece.
Inventors: |
Dick; Spencer B.; (Portland,
OR) ; Aldrich; Stuart; (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
|
Assignee: |
Precision Automation, Inc.
Vancouver
WA
|
Family ID: |
38603596 |
Appl. No.: |
12/260031 |
Filed: |
October 28, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11702905 |
Feb 5, 2007 |
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12260031 |
|
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|
10964553 |
Oct 12, 2004 |
7171738 |
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11702905 |
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Current U.S.
Class: |
700/171 |
Current CPC
Class: |
B27M 1/08 20130101; Y10T
29/5107 20150115; Y10T 29/5124 20150115; Y10T 29/5138 20150115;
Y10T 29/5145 20150115; Y10T 29/49996 20150115; Y10T 29/5143
20150115; F16B 2200/30 20180801; Y10T 29/49616 20150115; Y10T
83/162 20150401; Y10T 29/5136 20150115; Y10T 29/49963 20150115 |
Class at
Publication: |
700/171 |
International
Class: |
G06F 19/00 20060101
G06F019/00 |
Claims
1. A method of constructing a face frame component for a cabinet
comprising providing a cut list including dimensions of processed
pieces required for construction of face frames for cabinets,
providing an apparatus configured to cut length dimensions and to
rout a cavity in a work piece in a single pass through the
apparatus, and a computer connected to the apparatus, the apparatus
having a linear processing path, a pusher configured for reciprocal
movement along a length of the processing path to push a trailing
end of an elongate work piece having a long axis parallel to the
processing path, and a plurality of processing stations arranged
along the processing path downstream from the pusher, at least one
of the stations including a saw orientated perpendicular to the
processing path for cutting the work piece in a direction
perpendicular to the long axis of the work piece, and at least one
of the stations including a router bit configured to form a cavity
in the work piece, programming the computer with an optimization
program configured to calculate an optimum processing plan for a
work piece based on a starting length of the work piece, and
current requirements specified in the cut list stored in the
computer, entering the cut list into the computer, providing a
supply of work pieces for processing into dimensions specified in
the cut list, each workpiece being preprocessed into a
substantially straight form having a rectangular cross-section.
selecting a first work piece from the supply, inputting data into
the computer including the length of the first work piece,
calculating in the computer an optimum plan for processing the
first work piece to satisfy current cut list requirements, driving
the pusher, under computer control, along a length of the
processing path to push the trailing end of the first work piece
down the processing path toward the processing stations, cutting
the work piece, under computer control, perpendicular to the long
axis of the first work piece at a first processing station, and
routing a cavity in the first work piece at a second processing
station.
2. The method of claim 1, wherein the cavity created by the routing
step forms a mortise, further comprising the step of assembling a
face frame component for a cabinet by forming a mortise and tenon
joint between the first work piece and a second work piece.
3. The method of claim 1, wherein the cavity created by the routing
step forms a longitudinal groove, further comprising the step of
inserting a spacer element in the groove.
4. The method of claim 3, wherein the inserting step is performed
by shooting the spacer element toward the groove.
5. The method of claim 1 further comprising inputting data into the
computer indicating location of one or more defects including
knots, cracks, or discoloration within the work piece, wherein the
calculating step includes calculating an optimum plan for
processing the workpiece to satisfy current cut list requirements,
and removing the one or more defects.
6. The method of claim 4, wherein the shooting step is carried out
during the driving step.
7. The method of claim 3, wherein the spacer element is oversized
relative to a dimension of the groove.
8. The method of claim 3, wherein the programming step includes
programming the computer to determine which workpieces should
include spacer elements.
9. The method of claim 3, wherein the programming step includes
programming the computer to determine a location for a spacer along
a length of a workpiece.
10. The method of claim 1 further comprising the step of providing
a marking station along the processing path of the apparatus, and
marking the first work piece at the marking station to indicate a
position of attachment between a rail and a stile for a
cabinet.
11. The method of claim 1 further comprising the step of providing
a printing station along the processing path, and printing a label
for the first workpiece indicating a characteristic or future use
for the workpiece.
12. The method of claim 11, wherein the label is printed directly
on the first workpiece.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation patent application of U.S. patent
application Ser. No. 11/702,905 filed Feb. 5, 2007 which is a
continuation patent application of U.S. patent application Ser. No.
10/964,553 filed Oct. 12, 2004, now U.S. Pat. No. 7,171,738 issued
Feb. 6, 2007.
CROSS-REFERENCES TO RELATED MATERIALS
[0002] This application incorporates by reference the following
U.S. Pat. Nos. 491,307; 2,315,458; 2,731,989; 2,740,437; 2,852,049;
3,886,372; 3,994,484; 4,111,088; 4,144,449; 4,286,880; 4,434,693;
4,541,722; 4,596,172; 4,939,379; 4,658,687; 4,791,757; 4,805,505;
4,901,992; 5,042,341; 5,142,158; 5,201,258; 5,251,142; 5,254,859;
5,443,554; 5,444,635; 5,460,070; 5,524,514; 5,960,104; 6,216,574;
6,549,438; and 6,631,006.
[0003] This application also incorporates by reference the
following U.S. patent applications: Ser. No. 10/104,492, filed Mar.
22, 2002; Ser. No. 10/642,349, filed Aug. 15, 2003; Ser. No.
10/642,350, filed Aug. 15, 2003; Ser. No. 10/642,351, Aug. 15,
2003; Ser. No. 10/645,826, filed Aug. 20, 2003; Ser. No.
10/645,827, filed Aug. 20, 2003; Ser. No. 10/645,828, filed Aug.
20, 2003; Ser. No. 10/645,831, filed Aug. 20, 2003; Ser. No.
10/645,832, filed Aug. 20, 2003; Ser. No. 10/645,865, filed Aug.
20, 2003; Ser. No. 10/897,997, filed Jul. 22, 2004; and Ser. No.
10/958,690, filed Oct. 4, 2004, titled "System for Forming Dados,"
and naming Spencer B. Dick, as inventor.
[0004] This application also incorporates by reference the
following U.S. provisional patent application: Ser. No. 60/574,863,
filed May 26, 2004.
BACKGROUND
[0005] Many manufactured goods are constructed from components that
are cut from stock material, processed further, and then assembled.
For example, wood products, such as cabinets, often are constructed
in a series of operations including cutting components of the
appropriate length from stock lumber, modifying each component to
facilitate assembly (and/or to add functionality and/or improve
appearance), and then assembling the modified components.
Performing of these operations can be inefficient, even when one or
more of the operations are automated. For example, an automated saw
may use a computer to determine where to cut stock lumber for
construction of cabinets according to a user-supplied list of the
required lengths of cabinet components (i.e., a cut list). The
computer controls sites of cutting along the stock lumber based on
the cut list and in a manner that optimizes utilization of the
lumber to create the cabinet components. However, the cabinet
components are generally handled to reposition them between cutting
and further modification (such as drilling, marking, forming a
joint surface, etc.), adding substantial time and expense to the
construction of cabinets. A more efficient approach to processing
components from stock material thus is needed.
SUMMARY
[0006] The present teachings provide systems, including method and
apparatus, for processing workpieces driven automatically along a
linear path to a plurality of positions disposed substantially
along the linear path. In some embodiments, a workpiece may be
processed at one or more of the positions using two or more
processing stations, such as a first processing station that cuts
the workpiece into segments and a second processing station that
performs another processing operation on the workpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic view of an exemplary system for
processing workpieces driven along a linear path past a plurality
of processing stations disposed generally along the linear path, in
accordance with aspects of the present teachings.
[0008] FIG. 2 is a schematic view of a controller and data
input/output devices of the system of FIG. 1, in accordance with
aspects of the present teachings.
[0009] FIG. 3 is a flowchart of a sequence of operations that may
be performed in an exemplary method of processing workpieces at two
or more processing stations, in accordance with aspects of the
present teachings.
[0010] FIG. 4 is a view of an exemplary system for drilling and
cutting workpieces driven along a linear path past a drill station
and a saw station, in accordance with aspects of the present
teachings.
[0011] FIG. 5 is a view of selected portions of the system of FIG.
4, particularly the drill station and saw station and their
relationship to an exemplary workpiece, in accordance with aspects
of the present teachings.
[0012] FIG. 6 is a schematic side elevation view of selected
portions of another exemplary system for processing workpieces at a
plurality of processing stations, particularly showing a print
station printing indicia on a workpiece driven past the print
station, in accordance with aspects of the present teachings.
[0013] FIG. 7, is a plan view of the system of FIG. 6, taken
generally along line 7-7 of FIG. 6.
[0014] FIG. 8 is a somewhat schematic view of selected portions of
still another exemplary system for processing workpieces at a
plurality of processing stations, particularly showing a marker
station marking a workpiece with transverse lines, in accordance
with aspects of the present teachings.
[0015] FIG. 9 is a somewhat schematic, partially sectional view of
selected portions of yet another exemplary system for processing
workpieces at a plurality of processing stations, particularly
showing a spacer placement station firing spacer balls into a
longitudinal groove of a workpiece as the workpiece is moving past
the placement station, in accordance with aspects of the present
teachings.
DETAILED DESCRIPTION
[0016] The present teachings provide systems, including method and
apparatus, for processing workpieces driven automatically along a
linear path (a processing path) to a plurality of positions
disposed substantially along the linear path. In some embodiments,
a workpiece may be processed at one or more of the positions using
two or more processing stations. One of the processing stations may
be a cutting station, for example a saw station, that cuts through
the workpiece to create segments (a segmented form of the
workpiece). A computer may receive data about the workpiece, such
as its length, positions of one or more defects, if any, in the
workpiece, and a cut list defining a characteristic dimension
(e.g., the length) of each of a set of desired products. The
computer may select sites along the workpiece where cutting is to
be performed, according to the cut list and to optimize use of the
workpiece (and, optionally, to exclude one or more defects of the
workpiece from each of the workpiece products). The computer also
may control operation of a workpiece drive mechanism that moves the
workpiece along the linear path for cutting at the selected sites
by the cutting station to produce segments corresponding in length
to one or more of the desired products (unless slated to be
shortened by additional processing). Other processing operations
(such as drilling, marking, routing, sawing at another saw station,
sanding, deburring, fluid addition, member addition, etc.) also may
be performed on the workpiece, generally under control of the
computer, during a single pass of the workpiece past the processing
stations. Accordingly, the systems of the present teachings may
offer increased automation, more rapid workpiece processing, less
operator handling, and/or higher production efficiencies, among
others.
[0017] FIG. 1 shows an exemplary system 20 for processing
workpieces with two or more processing stations. System 20 may
include a drive mechanism 22 for moving a workpiece 24 along a
linear path 26. In the present illustration, drive mechanism 22 is
configured as a pusher mechanism or pusher 28 that engages a distal
end region 30 of the workpiece and advances (and stops) adjustably,
indicated in phantom outline at 32, to push the workpiece forward.
The drive mechanism may move the workpiece past two or more
processing stations disposed generally along and/or adjacent the
linear path. In the present illustration, system 20 includes three
processing stations 34, 36, 38 (labeled "A," "B," and "C,"
respectively). However, two, four, or more processing stations may
be included. The processing stations may modify the workpiece at
positions, shown at 40, substantially along the linear path to form
one or more workpiece products.
[0018] System 20 also may include at least one controller 42 (a
computer) in communication with drive mechanism 22, shown at 44,
and generally also in communication with each processing station,
shown at 46. A controller or computer, as used herein, is any
programmable electronic machine for processing information (data).
The controller is configured to control operation of the workpiece
drive mechanism, to move the workpiece automatically into position
for modification by the processing stations. In some examples, the
controller also may be configured to control operation of one or
more (or all) of the processing stations, to automate modification
of the workpiece during and/or after movement of the workpiece into
and/or through processing stations. Data thus may be received by
the controller and/or sent from the controller using communication
pathways, such as communication links 44, 46 and/or data
input/output devices 48. The terms "automatically" and "automated,"
as used herein, refer to operations or processes (or processing
stations) that do not require human intervention for their
execution (or actuation in processing). For example, processing a
workpiece automatically with a pusher mechanism and one or more
processing stations means that the pusher mechanism and the one or
more processing stations can operate in coordination to modify the
workpiece without human intervention after the pusher mechanism
begins moving the workpiece toward the processing stations. The
term "manually" or "manual," as used herein, refer to processes or
operations (or processing stations) that involve human intervention
for their execution (or actuation in processing). In some examples,
one or more of the processing stations may be operated manually
during processing, for example, a saw station that cuts workpieces
with manual movement of a power-driven blade of the station through
workpieces.
[0019] FIG. 2 shows an exemplary schematic configuration of
selected portions of controller 42 and connected input/output
devices 48.
[0020] Controller 42 may include a processor 60 and memory 62,
among other devices. Processor 60 may be configured to process
data, for example, by performing arithmetic, logical, and/or other
operations on the data. Memory 62 may include input data 64
received, for example, from communication links 44, 46 (see FIG. 1)
and/or input/output devices 48. Memory also may include
instructions 66, generally in the form of software, for processing
data and/or instructing operation of the workpiece drive mechanism,
processing stations, and/or other devices of the system.
[0021] Input data 64 may include any suitable data related to
workpieces, products, modes of processing, user-defined preferences
for processing or system operation, etc. Exemplary input data may
include product data 68 and workpiece data 70.
[0022] Product data 68 may be information about desired products
and/or about workpiece products already produced by the system,
among others. Information about desired products may include a cut
list 72 with cut list data corresponding to a characteristic
dimension (e.g., the length) of each desired product (and/or longer
precursors (of the desired products) that are slated for additional
shortening in the system, such as by processing of newly cut ends).
Accordingly, the cut list may define the spacing between cuts
within a workpiece and/or between a cut and the end of the
workpiece, among others. The cut list (and/or the product list)
also may provide data corresponding to the relative or absolute
number of each desired product that the system should produce.
Information about desired products also or alternatively may
include data corresponding to a list of other processing
operations, shown at 74, to be performed on workpieces. For
example, the list of other processing operations may include a
drill list with data corresponding to positions on desired products
at which holes should be formed (and/or the depth/angle of each
hole), a joinery list with data corresponding to joinery structures
(e.g., joint surfaces) to be created in desired products, a marking
list with data corresponding to positions at (and content of)
surface marks to be created on each desired product, etc.
Accordingly, the list of other processing operations may be related
to desired products having lengths formed by cutting workpieces,
although these other processing operations may be conducted before,
during, and/or after workpieces are cut into segments having
lengths corresponding (approximately or substantially) to desired
products. In some examples, other processing operations may be
specified by processing rules that allow processing positions to be
calculated for each desired product based, for example, on the
length of the desired product. Exemplary processing rules may
include processing at the longitudinal midpoint of a desired
product, processing at a constant spacing from the opposing ends of
a desired product, etc.
[0023] Workpiece data 70 may be information about any suitable
aspect of a workpiece to be processed by the processing stations of
the system. Exemplary workpiece data may include a characteristic
dimension (e.g., the length, width, and/or thickness, among others)
of the workpiece, grade of workpiece (and/or its material), type of
workpiece, composition, shape, appearance (such as its color),
defect data (e.g., position(s), type of defect, degree of defect,
etc.), and/or the like. Further aspects of workpieces and data that
may be input about workpieces are included in Sections IV and
V.
[0024] Instructions 66 may be configured to use input data 64 about
a workpiece and desired products, among others, to generate
processing instructions that control automated operation of the
workpiece drive mechanism and/or the processing stations (see FIG.
1).
[0025] Exemplary instructions may include an optimization algorithm
76. The optimization algorithm may be configured to optimize
utilization of each workpiece based on data about desired products
(and, optionally, based also on products already produced). In
particular, the optimization algorithm may be configured to
optimize utilization of each workpiece based on cut list 72.
Accordingly, the optimization algorithm may select sites along a
workpiece at which the workpiece will be cut into segments, based
on desired products indicated by the cut list. The sites may be
selected according to the length of the workpiece, the position(s)
and length of defects in the workpiece, and other aspects of the
workpiece, such as the grade of workpiece material. Optimization of
the use of a workpiece may include selecting cutting sites so that
workpiece defects, if any (as determined by a person operating the
system and/or automatically), are excluded from workpiece products
formed from the workpiece.
[0026] Other exemplary instructions may include a remainder
management algorithm 78 to manage processing of remainder material.
Remainder material, as used herein, is one or more segments of a
workpiece that will not be processed into workpiece products
corresponding to desired products. The remainder material may
include a defect and/or may be a portion of the workpiece too short
to form a product on the cut list after cutting sites have been
selected on the workpiece. The management algorithm may determine,
for example, whether each remainder segment should be cut into
smaller pieces or not. Accordingly, the management algorithm may
determine, for example, whether each remainder segment is thrown
away or salvaged. In some examples, the management algorithm may
manage sorting of workpiece products, alternatively or in addition
to managing cutting and/or sorting of remainder material. Further
aspects of processing remainder material for salvage or disposal
are included in U.S. patent application Ser. No. 10/645,828, filed
Aug. 20, 2003, which is incorporated herein by reference.
[0027] Additional exemplary instructions may include device drivers
80. Drivers 80 may be responsible for control signals or
instructions sent to the workpiece drive mechanism and/or the
processing stations, among others. A software driver for the
workpiece drive mechanism may control operation of this drive
mechanism and thus movement of a workpiece along a linear path.
Drivers for the processing stations may control operation of each
processing station, for example, by controlling a station drive
mechanism for each station. Exemplary aspects of control for the
workpiece drive mechanism (and/or workpiece), and/or processing
stations may include speed, acceleration, distance of travel,
starting position(s), stopping position(s), and/or
actuation/de-actuation times, among others. In some examples,
aspects of the controller, and particularly device drivers, may be
included in the workpiece drive mechanism and/or processing
stations.
[0028] Data input/output devices 48 may be disposed in
communication with the controller.
[0029] Exemplary input/output devices may include one or more user
interfaces 82, such as a keyboard, a keypad, a mouse, a screen,
and/or a joystick, among others, to allow an operator to input data
to the controller, for example, by pressing keys and/or through a
graphical user interface. Alternatively, or in addition, the
operator may input data more directly into controller memory from a
portable memory storage device holding input data that was added to
the storage device using another computing device.
[0030] Other exemplary input/output devices may include at least
one sensor 84, such as a distance, position, velocity, or activity
sensor, among others. The sensor may be configured, for example, to
permit an operator to input data about workpieces (e.g.,
dimensional, defect, and/or grade data, among others), and/or may
sense this data automatically (e.g., by sensing an end and/or
defect of the workpiece and/or by sensing machine-readable indicia
on the workpiece). In some examples, a sensor may be configured to
sense manual operation of a processing station by a person during
otherwise automated processing. For example, the sensor may inform
the computer that a person has performed a cut in a workpiece, so
that the computer can instruct the drive mechanism to advance to
workpiece for additional processing or output.
[0031] Addition exemplary input/output devices may include one or
more printers 86 to output data. The printer may be configured, for
example, to print data about workpieces, workpiece processing (such
as numbers/types of products, time of processing, etc.), user
preferences, etc. Alternatively, or in addition, the printer may be
configured to print labels for workpiece products. The labels may
be applied manually or automatically to the products. Further
aspects of label printing are included in U.S. patent application
Ser. No. 10/645,831, filed Aug. 20, 2003, which is incorporated
herein by reference. In some examples, a printing device (a
printhead) may be included in a processing station to apply a
colorant (such as ink) to a workpiece (see Examples 2 and 3).
[0032] In some examples, the input/output devices may include one
or more audio/visual devices 88. Each audio/visual device may be
configured to create an audible or visible signal for an operator
of the system. Exemplary audible signals may include a buzzer, a
bell, a tone, a whistle, a spoken word, and/or the like. Exemplary
visible signals may include a light(s). The light or lights may be
of different colors, intensities, positions, and/or flashing
durations/patterns, among others, to signal different information.
The signals may be configured to indicate any suitable aspect of
data input, data output, workpiece processing, and/or system
operation, among others. For example, the signals may indicate that
data (such as workpiece length, grade, defect position(s)) has or
has not been input successfully, that workpiece processing has been
initiated, that workpiece processing is complete, a malfunction of
the system, etc.
[0033] FIG. 3 shows a flowchart of method steps that may be
performed in an exemplary method 110 of processing workpieces at
two or more processing stations in a processing system. The steps
shown may be performed in any suitable order, in any suitable
combination, and any suitable number of times.
[0034] Inputs may be received, shown at 112. The inputs may be
received by a controller and may include any data related to a
workpiece to be processed, desired products, processing parameters,
system parameters, and/or the like. The inputs may be provided to
the controller from an operator, automatically (such as from a
sensor), and/or by data processing, among others.
[0035] Processing instructions may be determined based on the
inputs, shown at 114. The processing instructions may include any
aspects of how the workpiece drive mechanism, processing stations,
and/or other system devices operate. For example, the processing
instructions may include where (and/or when/how) the workpiece
drive mechanism (and generally the workpiece) starts and stops,
when (and/or where/how) the processing stations modify the
workpiece, and/or the like.
[0036] The workpiece may be positioned adjacent (and/or in) two or
more processing stations, shown at 116. A workpiece positioned
adjacent and/or in a processing station is disposed to be engaged
by a portion of the processing station and/or a component released
therefrom (such as an expelled component, e.g., ink, a fastener, a
spacer element, etc.).
[0037] The workpiece may be processed with each processing station,
shown at 118. The action of the processing stations forms one or
more workpiece products.
[0038] Further aspects of the present teachings are described in
the following sections, including, among others, (I) processing
stations, (II) drive mechanisms, (III) support/guide structures,
(IV) workpieces, (V) input of workpiece and product data, and (VI)
examples.
I. PROCESSING STATIONS
[0039] The systems of the present teachings each may include two or
more processing stations for processing workpieces. The term
"processing," as used herein, can be any action or set of actions
that result in structural modification of a workpiece. A structural
modification is any change in the shape, size, a surface aspect,
and/or other intrinsic property of a workpiece, for example, by
removing material from the workpiece, adding material to the
workpiece, deforming the workpiece, and/or changing the molecular
structure of the workpiece, among others. Accordingly, a processing
station is any portion of a system that can effect processing of a
workpiece. Each processing station generally includes a machine or
set of machines configured to perform a processing operation, and
an associated space in which the processing can be performed on a
workpiece. A system with two or more processing stations may
include distinct processing stations that perform two or more
different types of processing operations and/or that can perform
the same type of processing operation at different positions (for
example, at the same time).
[0040] A processing station may include a processing element that
engages a workpiece and/or ejects a material or projectile toward
the workpiece. Exemplary processing elements that engage a
workpiece may include a blade, a drill bit, a router bit, a pen, a
tip, a scribe, a brush, etc. Exemplary processing elements that
eject (or fire) a material or projectile toward the workpiece,
with, or more generally without workpiece contact, may include a
printhead, a sprayer, a dropper, a projectile gun, etc. (Exemplary
projectiles may include spacers, fasteners, joint members (e.g.,
dowels, biscuits, butterfly locks, etc.). and/or the like.
Processing elements may have any suitable disposition and/or
direction of travel relative to a workpiece. For example,
processing elements may be disposed above, below, laterally, and/or
adjacent an end of the workpiece (and/or a segment thereof).
Furthermore, processing elements may be movable translationally
and/or pivotably, in any suitable direction, including downward,
upward, transverse, oblique, and/or longitudinal motion, among
others, relative to the workpiece. This motion may position the
processing element at a suitable position along the length, width,
and/or depth of the workpiece, and in some examples (e.g.,
drilling, sawing, and/or routing, among others), may introduce the
processing element into and/or through the workpiece. Accordingly,
the processing elements may be configured to process faces, edges
and/or ends of workpieces.
[0041] Movement of processing elements, termed processing movement,
to dispose the elements in operational position relative to
workpieces, is generally computer controlled. However, processing
elements also may have a basic repetitive operating motion, such as
rotation, reciprocation, and/or travel along a looped path, among
others, which may be actuated separately by an element driver, and
thus may or may not be computer controlled.
[0042] The processing stations of a system may have any suitable
positional, functional, and operational relationship. Two or more
of the processing stations may be disposed upstream and downstream
of one another, generally along a processing path. Alternatively,
or in addition, two or more of the processing stations may have
about the same position along the processing path, for example,
when the processing stations occupy substantially nonoverlapping
positions around the workpiece. The processing stations may have a
fixed or adjustable positional relationship relative to one another
(and/or to the workpiece), particularly along the processing path
of the workpiece. Accordingly, in some examples, the processing
stations may be movable to the same position in the processing
path. The processing stations may perform processing operations on
a workpiece at any suitable relative times. For example, the
processing stations may operate in a sequential manner on the same
region of the workpiece (e.g., forming a cavity in a region with a
first station, and then placing a component in the cavity with a
second station), may operate at overlapping times on the workpiece
(e.g., cutting a workpiece at a saw station as the workpiece is
being drilled at a drill station), and/or may operate at
non-overlapping times on the workpiece (e.g., processing a
workpiece using a station and during a first time period (or a
first set of intervals), while the workpiece is moving, and
processing the workpiece using another station and during a second,
nonoverlapping time period (or set of nonoverlapping intervals),
while the workpiece is not moving). Processing operations performed
with two or more processing the stations, and workpiece movement,
all may be coordinated by computer.
[0043] A processing station may be configured for removing material
from a workpiece, to change the shape, size, and/or a surface
aspect of the workpiece. Exemplary processing stations for removing
material include a saw station (or another cutting station
including a laser, knife, flame, electron beam, etc.) for cutting a
workpiece, a router station for routing/milling a workpiece, a
scorer station for scoring the surface of a workpiece, a sander
station for smoothing the surface of a workpiece, a hole-forming or
drill station for forming a hole in a workpiece, a borer station
for widening a hole in a workpiece, a shearer station for shearing
a workpiece, a deburrer station for deburring a cut end and/or
other surface of a workpiece, a V-groove station for cutting a
V-groove in a workpiece, a punch station for punching a hole in a
workpiece, and/or the like.
[0044] A saw station may include any suitable type of saw, saw
blade, blade orientation, and blade movement. Exemplary blades may
include circular blades, band blades, and/or reciprocating blades,
among others. The blades may be configured to perform crosscuts
(generally transverse to the length of a workpiece; e.g., chop
saws), rip cuts (generally along the length of a workpiece; e.g.,
rip saws), miter cuts, dado cuts, angle cuts, nonlinear cuts, etc.
The saw station thus may include a motor that drives the blade
rotationally (e.g., circular saws), around a loop (e.g., band
saws), and/or back and forth (e.g., reciprocating saws). The driven
saw blade may be configured to be actuated for cutting a workpiece
by movement of the driven blade, generally computer-controlled
movement, in any suitable direction relative to a workpiece,
include translationally (e.g., a radial arm saw) and or along an
arc through pivoting motion (e.g., a chop saw, using an upward
and/or downward motion).
[0045] A drill station may include any suitable components and may
operate by any suitable approach to a workpiece. The drill station
may include a driver and a drill bit rotated by the driver.
Positioning of drill bit may be controlled by computer. This
positioning may be parallel to the long axis of the drill bit (to
control depth of drilling for through-holes or recesses), and/or
transverse to this axis. Accordingly, the depth of drilling may be
controlled, to form through-holes or recesses. Also, the
transverse, longitudinal, and/or vertical position of hole
formation on a workpiece may be controlled, as may the angle of
hole formation. Alternatively, or in addition, one or more aspects
of the position of the driver may be set manually before the
workpiece is processed.
[0046] A processing station may be configured to add material to a
workpiece, to change the shape, size, and/or a surface aspect of
the workpiece. Exemplary processing stations for adding material
include a print station for adding one or more surface marks (an
indicium or indicia) to a workpiece, a fastener station for adding
a fastener to a workpiece (such as a nail, screw, bolt, rivet,
bracket, hook, staple, dowel, biscuit, butterfly lock, spline,
etc.), a coating station for adding a surface coating or fluid
(e.g., paint, varnish, stain, sealant, glue, etc.) to a surface or
surface region of a workpiece, a spacer station for adding a spacer
element (e.g., a spacer ball, a block, a spline, etc.) to a
workpiece, an assembly station that connects (e.g., joins) the
workpiece with one or more other components, and/or the like.
[0047] A processing station may be configured to change the shape
of a workpiece by deformation of the workpiece. Exemplary
deformation may include bending, twisting, folding, compression,
stamping, and/or the like.
[0048] A processing station may be configured to change the
molecular structure of a workpiece. Exemplary operations that may
be used to change the molecular structure of a workpiece, either
globally or locally in the workpiece, may include heating, cooling,
exposure to electromagnetic radiation (e.g., visible light,
radiofrequency waves, microwaves, ultraviolet light, X-rays,
gamma-rays, etc.) or particle radiation, compression, and/or the
like.
II. DRIVE MECHANISMS
[0049] The systems of the present teachings each may include any
suitable number of drive mechanisms. Each drive mechanism may be
configured to move workpieces, workpiece products, a processing
station(s), a processing element of a processing station, and/or
the like. Drive mechanisms may be configured to move workpieces,
products, stations, and/or elements translationally, rotationally,
and/or pivotally, among others.
[0050] Operation of all or a subset of the drive mechanisms of a
processing system may be computer controlled. A computer thus may
control when a drive mechanism is actuated (movement starts),
de-actuated (movement stops), the speed of the drive mechanism,
acceleration of the drive mechanism, the direction of the drive
mechanism, and/or the like. The drive mechanism may include an
encoder that informs the computer of the position, speed, velocity,
acceleration, and/or direction of a drive mechanism.
[0051] Each drive mechanism may include a motor and a mechanical
linkage that couples operation of the motor to movement of a load.
The load may include a conveyor belt, a pusher element that engages
a distal end of the workpiece, and/or a portion or all of a
processing station, among others.
[0052] Any suitable motor(s) may be used in the drive mechanism.
Each motor may be an AC or DC electric motor, or may be air-powered
or gas-powered, among others. Exemplary motors may be single or
multiphase, universal, servo, induction, synchronous, stepper,
and/or gear motors. Each motor may rotary or linear.
[0053] The drive mechanism may employ any suitable linkage to the
load. Exemplary linkages may include a belt(s), a screw(s), a
gear(s) (e.g., a worm gear), a chain(s), a cable(s), a pulley(s), a
rod(s), a rack and pinion, and/or the like. The linkage also may
include a guide structure or track that directs and/or facilitates
sliding movement of the load. Accordingly, the guide structure or
track may include bearings or other elements that promote
sliding.
[0054] Workpieces may be moved along a linear path by a workpiece
drive mechanism. The workpiece drive mechanism may be configured to
engage any suitable surface of workpieces, such as a trailing end
(as in a pusher mechanism) to push the workpieces, a face or edge
(e.g., using a conveyor belt or conveyor wheels, among others) to
carry or propel the workpieces, and/or a leading end region, to
pull the workpieces. In exemplary embodiments, the pusher mechanism
may include a worm gear formed of a threaded rod, and a worm wheel
connected to a pusher carriage. Further aspects of pusher
mechanisms that may be suitable are described in U.S. patent
application Ser. No. 10/642,350, filed Aug. 15, 2003, which is
incorporated herein by reference.
[0055] Processed workpieces (products) may be moved away from
processing stations by any suitable drive mechanism(s). In some
examples, the workpiece drive mechanism also may be used to push
workpiece products through an outfeed site after their processing
is complete. Alternatively, or in addition, products may be moved
actively by a distinct product drive mechanism. The product drive
mechanism may include a conveyor, for example, to carry the
products farther, generally along the linear path of processing, to
move the products laterally, and/or to carry the products in a
direction generally opposite to the linear path. In some examples,
the product drive mechanism may include a pusher mechanism that
engages an edge of products and pushes them out of the linear path,
for example, down a ramp and/or onto a conveyor.
[0056] A processing portion of a processing station may be moved by
any suitable drive mechanism. For example, processing stations may
include drive mechanisms that move processing portion of the
stations relative to workpieces, for example, into engagement with
the workpieces or into suitable proximity to the workpieces. The
drive mechanisms thus may be operated, generally by computer
control, to position processing sites on a workpiece and/or to
conduct processing. In some examples, processing stations, such as
fixed printheads that print on workpieces, may lack a drive
mechanism so that they are stationary during operation.
[0057] A processing station may use distinct drive mechanisms for
driving a processing element in its basic operating motion (e.g.,
rotating a circular saw blade) and for driving processing of the
element with the processing element (e.g., moving the rotating
circular saw blade through a workpiece). The element drive
mechanism may or may not be computer controlled. However, the
processing drive mechanism generally is computer controlled.
[0058] The systems of the present teachings may include a clamp
mechanism that holds a workpiece in place as it is being processed
by a processing station. The clamp mechanism may include a clamp
member (or members) coupled to a drive mechanism, so that the clamp
member can be moved into engagement with the workpiece to effect
clamping, for example, when the workpiece is not moving, and can be
moved out of engagement with the workpiece to permit movement of
the workpiece by the workpiece drive mechanism. Operation of the
clamp drive mechanism may be under computer control (i.e.,
automated). An exemplary clamp mechanism is shown and described in
Example 1.
III. SUPPORT/GUIDE STRUCTURES
[0059] The systems of the present teachings may include various
support and/or guide structures that support, guide, and/or
facilitate movement of workpieces, processing stations, and/or
processing portions of processing stations. For example, the
support structures may include a table on which workpieces can
slide. The table may include a rail or rails that restrict lateral
movement of the workpieces, thus, along with the workpiece drive
mechanism, defining the linear path along which workpieces are
driven. The table and/or rails may include structures that
facilitate sliding, such as wheels or bearings, among others.
Processing stations may be attached to the table or to adjacent
support structures. Upward and/or lateral movement of workpieces
also or alternatively may be restricted or biased by a superior or
lateral wheel and/or a clamp mechanism (see Section II). Further
aspects of a wheel for biasing movement and/or creating drag are
described in U.S. Provisional Patent Application Ser. No.
60/574,863, filed May 26, 2004, which is incorporated herein by
reference.
IV. WORKPIECES
[0060] The systems of the present teachings process workpieces. A
workpiece, as used herein, is any piece of material that will be,
or is being, processed by a processing system. Accordingly, a
workpiece may be in a raw or "unprocessed" form (before any
processing by a system), in a partially processed form (during
and/or after partial processing by the system), or in a fully
processed form (after processing of the workpiece by the system has
been completed and/or the workpiece has passed through the system).
Each processing station of a system thus may process the raw form
of the workpiece, a partially processed form of the workpiece (such
as a workpiece cut into smaller pieces or segments (a segmented
form of the workpiece) and/or modified otherwise), or both. The
fully processed form of a workpiece, as used herein, is termed a
workpiece product or product. Although "fully processed" by a first
pass through the system, a product may be processed additionally
outside the system or during a second pass through the system.
[0061] A workpiece may have any suitable composition. Workpieces
thus may be formed of wood, metal, plastic, fabric, cardboard,
paper, glass, ceramic, or a combination thereof, among others. The
composition may be generally uniform or may vary in different
regions of a workpiece (e.g., a wood workpiece with a vinyl
coating). Exemplary workpieces are wood products, for example, sawn
lumber, wood laminates, wood composites, etc. Other exemplary
workpieces are metal sheets or strips.
[0062] A workpiece may have any suitable shape and size. Generally,
the workpiece is elongate, so that the workpiece can be moved along
a linear processing path that is parallel to the long axis of the
workpiece. However, in some embodiments, the workpiece may not be
elongate and/or may not be oriented so that the long axis of the
workpiece is parallel to the linear processing path. The workpiece
may have any suitable length. Exemplary lengths are based on
available lengths of stock pieces, such as stock lumber of about
six feet to twenty feet in length, for the purpose of illustration.
In some examples, the workpiece may have a rectangular cross
section, opposing ends, edges, and faces.
[0063] A workpiece may be of generic stock or may be pre-processed
according to a particular application, before processing in a
system. For example, the workpiece may be a standard piece of raw
lumber. Alternatively, the workpiece, before processing by the
system, may include one or more holes, grooves, ridges, surface
coatings, markings, etc., created, for example, based on desired
features of products to be formed by the system.
V. INPUT OF WORKPIECE AND PRODUCT DATA
[0064] Data about workpieces and/or desired products may input into
a system, by communicating this data to a controller. The data may
be input through any suitable user interface.
[0065] Any suitable data may be input about a workpiece. The data
may relate to the type of workpiece, one or more characteristic
dimensions (e.g., the length, width, and/or thickness, among
others) of the workpiece, grade of workpiece material (e.g., high
grade, medium grade, low grade, etc.), composition, shape, defect
data (e.g., defect position(s), degree of defect, etc.), color,
and/or the like.
[0066] Workpiece data may be input through the action of a person
and/or automatically. Accordingly, the workpiece data may be input
through a computer interface, such as a graphical user interface, a
keyboard, a keypad, etc. Alternatively, or in addition, the
workpiece data, particularly one or more characteristic dimensions
and/or defect data about of the workpiece, may be input through a
controller-linked measuring device. The measuring device may
include an optical measuring device (e.g., see Example 1).
Alternatively, or in addition, the measuring device may be an
encoder-based measuring device that an operator can slide parallel
to the length of a workpiece and selectively actuate, for example,
by pushing a button, to send information about the relative
position of the workpiece ends, one or more defects, and/or other
workpiece features to the controller. Exemplary measuring devices
that may be suitable for use in the processing systems of the
present teachings are described in the patents and patent
applications identified above under Cross-References, which are
incorporated herein by reference,
[0067] Any suitable data may be input about desired products to
provide a product list. The data may correspond to the length of
each product (a cut list), the absolute or relative number desired
of each product, type(s) of processing to be included in each
product, position(s) where processing should be performed for each
product, order of processing operations for each product, etc. In
some examples, the data may correspond to a destination for the
product, such as a bin or chute, among others, to which the product
should be direct automatically, so that products are sorted after
processing.
VI. EXAMPLES
[0068] The following examples describe, without limitation, further
aspects of the present teachings. These aspects include exemplary
systems for processing workpieces driven along a linear path
through (and/or adjacent) two or more processing stations, and
exemplary processing stations for such systems, among others.
Example 1
[0069] This example describes an exemplary system for drilling and
cutting workpieces driven along a linear path; see FIGS. 4 and
5.
[0070] FIG. 4 shows an exemplary system 130 for automated cutting
(sawing) and drilling of workpieces driven along a linear path.
System 130 may include a pusher mechanism 132 configured to push a
workpiece 134 along a linear path 136. System 130 also may include
a saw station 138 and a drill station 140 disposed at spaced
positions generally along the linear path. The pusher mechanism
thus may position the workpiece suitably along the linear path so
that the saw station and drill station can saw and drill the
workpiece to form one or more workpiece products 142. The workpiece
may be supported by a table 144, guided by one or more guide rails
146, and held in position by a selectively actuable clamp mechanism
148.
[0071] System 130 may include one or more controllers (computers)
for automating aspects of system operation. For example, the system
may include a local controller 150 and a project management
controller 152. The local controller may be configured to send
instructions to, and thus control, each of the pusher mechanism,
the saw station, and the drill station, so that movement of the
workpiece along the linear path, cutting the workpiece, and
drilling the workpiece each are automated. The local controller
also may send instructions to, and thus control selective actuation
(and de-actuation) of, the clamp mechanism. The local controller
further may be configured to receive input data about workpieces
and/or desired products, among others, and may optimize and
coordinate processing of workpieces by the saw station and the
drill station according to the products desired. Project management
controller 152 may be used remotely from the local controller, to
store, edit, combine, or modify data about desired products (and/or
workpieces), such as cut/drill lists, prior to downloading one or
more of the lists to the local controller.
[0072] Data (such as length, grade, type, etc.) about workpieces
and/or system operation may be input by any suitable mechanism. For
example, local controller 150 may include a keypad 154 through
which data may be input in by an operator of the system.
Alternatively, or in addition, system 130 may include an optical
measuring device 156 that inputs data to the local controller based
on a path followed by light 158. For example, interruption of the
light path by an end of a future workpiece 160 to be processed
after current workpiece 134, and/or by an object placed manually
(using human energy) in the light path, may be used to input the
length of the future workpiece and/or a position(s) of a defect 162
along the length of the future workpiece, among others. An
audio/visual device, such as an indicator light 164, may be used to
signal successful (and/or unsuccessful) input of data, such as
length and/or defect positions, to the local controller. Signals,
such as processing start or stop signals, among others, also may be
input by using the optical measuring device as a "virtual keyboard"
and/or with other user interfaces, such as keypad 154, a graphical
user interface, or a foot pedal 165, among others.
[0073] System 130 also may include other devices or features to
facilitate workpiece management. For example, the system may
include a printer 166 configured to print labels 168 for manual or
automatic application to workpiece products. System 130 also or
alternatively may include an outfeed structure 169 configured to
receive workpiece products, salvage pieces, and waste pieces. The
outfeed structure may include a waste opening 170 sufficient to
selectively receive only waste pieces. Accordingly, the system may
be configured to cut pieces, designated for disposal, to a size
small enough to fit through the waste opening. Further aspects of
processing and separating salvage and waste pieces are described in
U.S. patent application Ser. No. 10/645,828, filed Aug. 20, 2003,
which is incorporated herein by reference.
[0074] FIG. 5 shows selected portions of system 130, particularly
portions of saw station 138 and drill station 140, and their
relationship to workpiece 134. Saw station 138 may include a saw
blade 180 driven rotationally or reciprocably by a motor. Control
of the saw station by the local controller may include moving the
saw blade into engagement with the workpiece, for example, by
instructing the saw station to move the saw blade upward,
transverse, and/or downward to (and/or through) the workpiece. In
the present illustration, the saw blade is instructed to cut the
workpiece by transverse movement, shown at 181.
[0075] Drill station 140 may include a drill bit 182 driven to
rotate and/or pivot by a motor to form one or more holes 183 in the
workpiece. Operation of the drill station by the local controller
may include instructing the drill station to move the drill bit
into engagement with the workpiece, for example, by movement that
is upward, transverse, oblique, and/or downward into (and/or
through) the workpiece. In the present illustration, the drill bit
approaches and moves away from the workpiece by downward and upward
movement, respectively, along a vertical axis, shown at 184. The
depth of drilling may be controlled by how far the drill bit is
advanced into the workpiece. The drill station also may include a
drive mechanism that moves the drill bit along a transverse axis,
shown at 186 (and/or a longitudinal axis or vertical axis, among
others), to adjust the transverse (and/or longitudinal or vertical)
position at which the drill bit enters the workpiece. In some
examples, the drill station may include a drive mechanism that
permits automatic adjustment of the angle at which the drill bit
drills the workpiece. In the present illustration, the drill
station is closer to the pusher mechanism than the saw station.
However, in alternative embodiments, the saw station may be closer
to the pusher mechanism than the drill station, or they may be
disposed at about the same distance from the pusher mechanism.
[0076] Clamp mechanism 148 may include a drive mechanism 188. The
drive mechanism may move the clamp mechanism along an axis, shown
at 190, that is transverse to the linear processing path, for
example, a horizontal or vertical axis. The controller may be
configured to instruct drive mechanism 188 when, where, and/or how
to move, thus controlling its operation.
Example 2
[0077] This example describes an exemplary workpiece processing
system with multiple processing stations, including a print station
for printing indicia on a workpiece driven past the print station;
see FIGS. 6-7.
[0078] FIG. 6 shows a side view of a workpiece processing system
210 including a print station 212. The print station may be
configured to print indicia on a workpiece 214 driven along a
linear path 216. The workpiece may be supported during printing and
other processing by a support structure, such as a table having a
horizontal support surface 217. The print station may include a
printhead 218, for example, an inkjet printhead configured to fire
ink droplets 220 onto a surface of the workpiece, for example,
upper surface 222. The printhead may include a plurality of
nozzles, from which individual droplets may be fired, such as by
actuation of thin-film firing elements (e.g., thin-film heater
elements and/or piezoelectric elements, among others). The print
station may be fixed or movable during operation, for example,
movable transverse to the linear path of workpiece movement. If
fixed, the print station may print indicia while the workpiece is
moving or not moving along the linear path. Operation of the print
station while the workpiece is moving may increase the speed of
workpiece processing, relative to printing only when the workpiece
is stopped. In some examples, operation of the printhead may be
coordinated with the position of the workpiece, based on an encoder
in the workpiece drive mechanism.
[0079] FIG. 7 shows a plan view of system 210, taken generally
along line 7-7 of FIG. 6. In the present illustration, workpiece
214 includes fully printed indicia 224 where the workpiece has
advanced past the print station, and partially printed indicia 226
in the process of being printed by the print station. The indicia
or surface marks may include one or more lines 228, one or more
alphanumeric characters 230, one or more words, a bar code, a
symbol, and/or the like. The indicia may be used, for example, to
identify products and/or to guide additional processing or assembly
of products. For example, in the present illustration, characters
"A5" may identify a particular product or a particular end of a
product. The characters (or other indicia, such as colors, symbols,
etc.) also or alternatively may indicate which component (e.g., by
name or part number) is to be assembled with the marked product,
and vice versa, so that pairs of products may be marked to identify
their partners for mating with one another. Line 228 may define,
for example, an accurate position at which another component is to
be attached to the workpiece (see Example 3).
Example 3
[0080] This example describes an exemplary workpiece processing
system with multiple processing stations, including a marking
station for placing a visible surface mark (an indicium or indicia)
on a workpiece driven past the marking station; see FIG. 8.
[0081] System 250 may include a marking station 252 that can place
one or more surface marks such as lines 254 on a workpiece 256. The
marking station may include a marking instrument, such as a pen
258, an inkjet device (see Example 2), or a scoring device (such as
a scribe or sharp-pointed awl), among others, that creates a
surface mark with ink (or another colorant of any suitable color,
including black) or by scratching the workpiece surface, as the
marking instrument moves across the workpiece. The marking
instrument may be configured to form a mark that extends linearly
(or nonlinearly) in a direction orthogonal, oblique, or parallel to
the linear path 260 followed by the workpiece. An orthogonal mark
may be formed by orthogonal movement of the marking instrument
while the workpiece is not moving. Alternatively, or in addition,
an orthogonal mark may be formed while the workpiece is moving, by
oblique movement of the marking instrument, shown at 262, for
example, along an obliquely disposed guide rail 264. The oblique
movement may have an angle, for example 45.degree., and a speed
selected so that the speed of forward movement of the workpiece
along the linear path matches the speed of the marking instrument
for travel parallel to the linear path. Alternatively, an oblique
mark may be formed while the workpiece is moving or not moving. In
some examples, the marking instrument may be replaced with a
cutting instrument, such as a saw, to provide a flying crosscut
that is created as the workpiece is moving. In any case, operation
of the marking instrument or cutting instrument may be controlled
by a computer and coordinated with operation of a drive mechanism
that moves the workpiece along a linear path.
[0082] System 250 may be useful, for example, in forming parts for
kitchen cabinets. Kitchen cabinets generally have a face frame that
sits behind doors and/or drawers. The face frame may have a top
rail, a bottom rail, and one or more intermediary rails each
attached to opposing stiles. The position for future attachment of
the intermediary rails may be marked on a workpiece (particularly a
portion of the workpiece corresponding to a future stile) using
marking station 252 of system 250. In some examples, marks may be
placed on a workpiece before (and/or during and/or after) the
workpiece is cut by a saw station of a processing system.
Example 4
[0083] This example describes an exemplary workpiece processing
system with multiple processing stations, including a spacer
placement station; see FIG. 9.
[0084] System 280 may include a spacer placement station 282 that
adds spacer elements (such as spacer balls 284, foam blocks, one or
more rubber splines, etc.) to a workpiece 286. The spacer elements
may be used, for example, to allow a panel in a frame and panel
door to be free-floating, to allow the panel to expand and
contract, and/or to dampen panel rattling, among others. The spacer
elements may be configured to be received in a cavity formed in the
workpiece, for example, a longitudinal groove 288. The longitudinal
groove or other cavity may be formed upstream of the spacer
placement station within system 280, for example, using a rip saw
or a router that is oriented to cut longitudinally (with or without
concurrent workpiece movement). Alternatively, the groove or other
cavity may be formed outside of system 280 before the workpiece is
processed by the system. The spacer placement station 282 may be
configured to fire the spacer elements, shown at 290, at the
workpiece without direct contact with the workpiece, as shown in
the present illustration. For example, the spacer placement station
may include a modified paint ball gun or similar firing device that
can fire the spacer elements at the workpiece. Accordingly, in some
examples, the spacer elements may be added to the workpiece while
the workpiece is moving (and, generally, with the spacer placement
station not moving), to save processing time. The spacer placement
station may fire spacer elements vertically, as shown in the
present illustration, horizontally, or along any other suitable
path. Alternatively, a spacer(s) may be pressed into the groove or
other cavity. In some examples, the spacer elements may be slightly
oversized, so that they deform and stay in position when placed
into the groove or other cavity.
[0085] Controller software may be configured to calculate where
and/or when spacer elements should be fired at workpieces, as the
workpieces are moving past the spacer placement station. For
example, positions along a workpiece at which spacer elements are
to be added may be determined by the controller software according
to stored specifications of desired products. In particular, the
controller software may determine which product or products are
being produced from the workpiece, which of the produced products,
if any, should include spacer elements, and what position or
positions along the length of each product should include a spacer
element. The positions of spacer elements may be predefined or may
be calculated "on the fly." In an exemplary embodiment, spacer
balls are placed three inches from each end of rails and two inches
from each end on stiles. The software thus may include an algorithm
that determines the length and part description of each product to
be formed from a workpiece, and based on these two factors,
calculates both the placement and frequency of spacer elements to
be inserted and in turn the actual ordinate positions along the
length of the workpiece. Accordingly, the spacer elements may be
added to selected workpieces automatically and at predefined
positions within these selected workpieces, in some cases while the
workpieces are moving and/or without contacting the workpieces with
the spacer placement station.
Example 5
[0086] This example describes exemplary workpiece processing
systems with multiple processing stations, including a station for
forming a joint surface.
[0087] Joints are sites where two or more components are joined
together. Each component includes a joint surface that mates with a
complementary joint surface of an adjacent component. Exemplary
joint surfaces formed by workpiece processing may be joined with
each other to produce finger joints, miter joints, mortise and
tenon joints, dovetail joints, dado joints, lap joints, splined
joints, tongue and groove joints, and/or the like.
[0088] A joint surface for joining to a complementary joint surface
may be formed by removing material from any suitable surface of a
workpiece using the systems of the present teachings. Accordingly,
the joint surface may be formed on an end of a workpiece, an edge
of a workpiece, and/or a face of a workpiece. For example, a
mortise for a tenon (or a tenon for a mortise) may be routed
automatically from a face, edge, or end of a workpiece. In some
examples, the joint surface may be formed as a workpiece is cut,
for example, a butt joint surface formed by an orthogonal crosscut,
or a miter joint surface formed by a miter cut. In some examples,
the joint surface may be formed on a cut end produced by cutting
the workpiece in a system of the present teachings. For example, a
finger joint surface may be formed with the newly cut end of a
workpiece using a finger joint cutter after the workpiece has been
cut by a saw station. After cutting, the newly created ends of the
leading and trailing pieces may be separated, for example, by
advancing the leading piece with a conveyor. The leading and/or
trailing piece then may be clamped in position and automatically
processed with a station that cuts finger joints.
Example 6
[0089] This example describes exemplary workpiece processing
systems with multiple processing stations, including a station for
forming a cavity and another station for inserting a joining member
into the cavity.
[0090] Joints may be strengthened by using joining members that
span joints. Such joining members may strengthen joints, for
example, by increasing the surface area of a joint (and thus the
surface area for a glue) and/or may swell after their installation,
among others. Exemplary joining members include dowels, biscuits
(used, for example, to span miter joints in frames), butterfly
locks, or the like.
[0091] Processing systems of the present teachings may include
processing stations configured to install joining members into
workpieces automatically. The systems may include a processing
station that forms a receiver cavity in a workpiece, and another
processing station that inserts the joining member into the
receiver cavity. The receiver cavity and the joining member may
have complementary structure, so that a portion of the joining
member fits into the receiver cavity, sometimes relatively snugly.
In some examples, the joining member may include a coating of an
adhesive when it is inserted. Alternatively, the receiver cavity
may be processed at a glue station at which glue is injected
automatically into the receiver cavity before the joining member is
inserted. A partner component of the processed workpiece, with a
complementary joint surface then may be joined with the workpiece
and its joining member, to complete the joint. Joining the partner
component may be performed outside the processing systems or
automatically by the processing systems.
Example 7
[0092] This example describes exemplary workpiece processing
systems with multiple processing stations, including a drill
station for forming a pocket hole in a workpiece.
[0093] Pocket holes are obliquely oriented holes that may be used,
for example, to receive fasteners, such as screws, to secure a
joint, such as a butt joint. The systems of the present teachings
may be used to form pocket holes automatically. In some examples,
the systems also may include a saw station. The pocket holes near
an end of a workpiece product may be formed before or after the
workpiece is cut. In exemplary embodiments, pocket holes configured
to receive screws to join face frame members are drilled after
cutting a workpiece to length.
Example 8
[0094] This example describes exemplary workpiece processing
systems with multiple processing stations for processing workpieces
formed of metal.
[0095] The systems may be configured to cut and remove burrs from
metal. Accordingly, the systems may include a cutting station (such
as a saw station) and a deburring station. The systems may cut a
metal workpiece to produce a newly cut end, and then may move the
workpiece to the deburring station to remove any sharp edges of the
newly cut end. The deburring station may include, for example, a
rotating metal brush and/or a rotating wheel with sandpaper flaps,
among others.
[0096] The systems may be configured to cut metal and then notch
the newly cut end. Accordingly, the systems may include a cutting
station (such as a saw station) and a notching station. After
cutting a workpiece to produce a newly cut end, the systems may
move the workpiece to the notching station for notching for the
newly cut end. The resultant notched product may be suitable, for
example, as a structural member of a window blind. The notched end
may be configured to receive an end cap, so that a fastener or a
string, among others, can be received in the notch.
[0097] The systems may be configured for automatic insertion of
rivets. The rivets may include fastener structure, for example, a
female or male thread, or a bracket, among others. The rivets may
be inserted into a workpiece before, during, and/or after the
workpiece is cut to length.
[0098] The systems may be configured for automaticaly tapping holes
(that is, forming a thread in the holes). The systems may include a
drill station and a tap station. A hole may be drilled
automatically in a metal workpiece and then tapped afterward. In
some embodiments, the tap station may be disposed downstream of the
drill station. In some embodiments, the drill station and the tap
station may be configured to drill and tap a hole while the
workpiece is in the same position, that is, without moving the
workpiece between operations.
[0099] The systems may be configured to automatically place
fasteners into holes. The systems may include a drill station and a
fastener placement station. After a hole is drilled in a workpiece,
the fastener placement station may press a self-clinching fastener,
such as PEM stud or nut, into the hole.
[0100] The systems may be configured to deform metal workpieces
automatically. The systems may include a cutting station (such as a
saw station) and a deformation station. Before, during, and/or
after a workpiece is cut, the workpiece may be deformed, for
example, bent, twisted, stamped, formed, etc. Deformation may be
conducted, for example, by a press brake.
[0101] The systems may be configured to punch holes automatically.
The systems may include a cutting station (such as a saw station)
and a punch station. Before, during, and/or after a workpiece is
cut to length, holes may be punched in the workpiece. Punching may
be suitable, for example, in the window industry to provide an
attachment site within an aluminum, perimeter frame member for an
intermediate frame member of a window frame.
Example 9
[0102] This example describes exemplary workpiece processing
systems with multiple processing stations that process workpieces
for assembly of miter-fold boxes.
[0103] The systems may include a V-grooving machine and a glue
station. The systems optionally may cut a workpiece to length. The
V-grooving machine may form V-shaped transverse grooves in a face
of the workpiece, before, during, and/or after cutting the
workpiece to length. The grooves generally do not extend to the
opposing face of the workpiece, for example, leaving a plastic
backing of the workpiece uncut. The glue station then may apply
glue to the V-grooves. The grooved workpiece with glue then may be
folded to mate opposing surfaces of each V-groove, to form the
sides of a box, optionally in the presence of a panel that fits
into longitudinal grooves disposed on the sides. Folding may be
performed automatically by the system, or manually or automatically
outside the system. This resulting box may provide a drawer or
speaker box, among others.
Example 10
[0104] This example describes exemplary workpiece processing
systems with multiple processing stations that process workpieces
for bending.
[0105] In the packaging industry, corner cushioning pieces (e.g.,
formed of cardboard or foam) may need to be cut to length from
stock, and scored for bending. The systems thus may include a
cutting station and a scoring station, which may operate in any
suitable order on a workpiece.
Example 11
[0106] This example describes exemplary workpiece processing
systems with multiple processing stations and configured to sort
processed products. The systems may include various chutes or gates
that may be operated automatically. Operation of the chutes or
gates may be determined by a sorting algorithm that controls
sorting of workpiece products according to product identity,
product type, sets of related products, etc., so that the products
are sorted into appropriate bins.
Example 12
[0107] This example describes exemplary workpiece processing
systems with multiple processing stations, including a station for
boring/drilling holes for attaching hinges. Hinge holes may be
formed in door frame members and face frame members automatically,
before, during, and/or after cutting the members to length.
Example 13
[0108] This example describes exemplary combinations of processing
stations that may be included in the systems of the present
teachings.
[0109] A processing system may include any suitable combination of
two, three, four, or more processing stations, such as any of the
processing stations of the present teachings. In some examples, the
processing system may include a cutting station, such as a saw
station, and at least one other processing station. The at least
one other processing station may include a marking station, a
printing station, a drilling station, a router station, a deburring
station, a scoring station, a fluid-addition station (for
application of paint, glue, varnish, etc.), a member addition
station (for addition of one or more members, such as a dowels,
biscuits, butterfly locks, fasteners, spacers, labels, etc.), a
shearing station, a deformation station, a punching station, a
folding station, a cutting station (such as a second saw station),
a sanding station, and/or the like. In some examples, the
processing system may include a cutting station (such as a saw
station) and a marking station (such as a scoring, printing, or
line-drawing station for creating a surface mark on a workpiece),
and at least a third processing station (such as a drill station, a
second cutting station, a routing station (with a router that
removes material from the workpiece), a fluid-addition station, a
member-addition station, etc.).
[0110] The stations may have any suitable disposition relative to
each other and relative to a workpiece drive mechanism. In some
examples, a first station may be disposed in a first position
closest to the drive mechanism, a second station may be disposed in
a second position that is spaced farther from the drive mechanism
than the first position, and, optionally, third and/or higher order
stations may be disposed in third and higher positions disposed
farther from the workpiece drive mechanism than lower order
positions. Each of the first, second, third, fourth, or higher
order station may be a cutting station, a drill station, a marking
station, a router station, a member-addition station, a fluid
addition station, or any other processing station described herein.
In some examples, first and second processing stations may be
disposed with the second processing station closest to the drive
mechanism, that is, so that regions of a workpiece are moved
through the second processing station before the first processing
station.
[0111] The disclosure set forth above may encompass multiple
distinct inventions with independent utility. Although each of
these inventions has been disclosed in its preferred form(s), the
specific embodiments thereof as disclosed and illustrated herein
are not to be considered in a limiting sense, because numerous
variations are possible. The subject matter of the inventions
includes all novel and nonobvious combinations and subcombinations
of the various elements, features, functions, and/or properties
disclosed herein. The following claims particularly point out
certain combinations and subcombinations regarded as novel and
nonobvious. Inventions embodied in other combinations and
subcombinations of features, functions, elements, and/or properties
may be claimed in applications claiming priority from this or a
related application. Such claims, whether directed to a different
invention or to the same invention, and whether broader, narrower,
equal, or different in scope to the original claims, also are
regarded as included within the subject matter of the inventions of
the present disclosure.
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