The present disclosure relates generally to apparatus, systems, and methods for machining materials, and more particularly to apparatus, systems, and methods for cutting, jointing, and fitting wood materials.
There are many situations in which it is desired to cut wood according to particular specifications, including geometrically complex specifications, such as curves, tapers, bevels, etc. For example, wooden barrels, such as those used in the production of wine or whiskey, are constructed from a plurality of discrete wood pieces formed into staves and head planks. Staves are cut or otherwise formed in a particular manner (e.g., curved, tapered, and beveled) so that a plurality of the discrete staves can be circumferentially arranged to form the outer body of individual wooden barrels. Similarly, the head planks are cut and fit together to form a flat circular end cap on each end of the barrel. End caps thus form the top and bottom of such barrel.
In the preparation of the wooden barrel, the head planks must be substantially flat and defect free, otherwise the appearance and functionality of the barrel may be compromised.
Known systems require a pre-machined plank or wood piece with flat, defect-free joint to be presented to the machine for a joint to be made. This is either done using a vision system and automated cutting, or manually by an operator. However, known machines require even further inspection after the jointing is done which either creates excessive rework or wastes good wood that is unnecessarily removed to reduce rework.
It is desirable, therefore, to provide apparatus, systems, and methods for wood-cutting that provide adequate precision to the cutting process to allow wooden barrels to be attractive, liquid tight, and with a minimum amount of waste product produced during manufacturing.
In one embodiment, a device for machining material, includes a rotatable turret including a plurality of plank holding positions, each plank holding position including a plank holding device. A projector is configured to project at least one cut line on a first surface of a plank. A cutting device is positioned at a second location adjacent to the rotatable turret, the cutting device includes a cutting tool configured to cut a trim section along a length of a second surface of the plank adjacent the first surface to establish a substantially planar portion of the second surface and/or remove one or more defects of the plank. A sensor is configured to scan the second surface of the plank and determine whether the substantially planar portion is within a predetermined tolerance. A jointing device is positioned at a first location adjacent to the rotatable turret, the jointing device includes a joint cutting tool configured to cut at least one groove at a location on the second surface.
In another embodiment, a method for machining material from a plank includes placing a plank in one of a plurality of holding devices of a rotatable turret, wherein the turret has a plurality of discrete stations, each station includes at least one of the holding devices. The turret is rotated to position the plank at a projection station, the projection station includes a projector, and projecting at least one cut line on a first surface of the plank using the projector. The turret is rotated to position the plank at a cutting station, the cutting station includes a cutting device configured to cut a trim section from a second surface of the plank to form a substantially planar portion. The turret is rotated to position the plank at a scanning station, the scanning station including a sensor configured to scan the second surface of the plank that is adjacent the first surface. The scanner is used to determine whether the substantially planar portion is within a predetermined tolerance. The turret is rotated to position the plank at a jointing station, the jointing station comprising a jointing device configured to cut at least one groove along the second surface of the plank. A groove is cut in the second surface of the plank along a location of where the cut line was projected onto the first surface of the plank.
The present disclosure describes embodiments of an apparatus and system for machining material, and methods therefor, that is capable of improving quality, safety, and waste during the manufacture of wooden barrels. More specifically, the apparatus and system for machining material disclosed herein may leverage the skill of trained operators in optimizing the placement of wood pieces into the materials machining system to reduce the instance of defects, waste, and improve performance of barrel end caps. Although the apparatus and system for machining material disclosed herein is described as cutting head planks for forming end caps of wooden barrels, it should be readily understood that the apparatus, system, and methods may be used to cut other wood pieces, or other rigid materials in other wood-working fields, such as furniture production or any other field wherein a number of substantially flat pieces of material are joined together to form a surface.
Reference is now made to the drawings and in particular to
Wood used to form the different parts of barrels, such as staves 60 and head planks 78 of barrel 70, are typically formed from oak (e.g., white oak). However, the barrel-forming staves 60, the head planks 78 and/or other wood pieces used for other purposes of the barrel 70 may be formed from any suitable wood or other material that allows the apparatus, systems, and resulting wooden barrel of this disclosure to function as provided herein. The staves 60 and the head planks 78 used to form barrels should generally be free from imperfections such as knots and sap. Imperfections in one or more of the staves 60 or the head planks 78 can compromise the function and aesthetics of the resulting wooden barrel.
To form the wooden barrel 70 as illustrated in
Either during or after the drying, the barrel 70 is “toasted”, or charred, on an interior surface 80 thereof. The level of toasting/charring affects the final flavor of whatever liquid (e.g., wine, whiskey) is aged therein.
The head rings are removed, and the end caps 84 (or “heads”) of the barrel 70 are installed. As used herein, “rings” may also be referred to as “hoops.” At this point, a plurality of final rings 72 are added to the barrel. For example and as seen in
Turning now to
In one embodiment, the materials machining device 100 includes a turret 102 configured to rotate about a central axis 106 in a direction of rotation R. The turret 102 includes a plurality of stations 108, including individual stations 108A-108X as described in more detail below. In the exemplary embodiment shown in
In one suitable embodiment, the head plank 78 is translated, or otherwise moved, into a proper position to be held (e.g., clamped) by the holding device 110. In one embodiment, a two-stage clamping process is used to properly position head plank 78 for machining. In this embodiment, the holding device 110 includes a two-stage clamping mechanism that includes a first clamping mechanism that applies pressure to one or more surfaces of head plank 78 to limit movement of the head plank 78, and then the first clamping mechanism moves together with head plank 78 to a second clamping mechanism of the holding device 110 for machining. In one embodiment, the holding mechanism 110 applies a pressure in a first direction Dl to the head plank 78 against a stationary plate 113. Accordingly, cut lines 114, 115 (described below) can be properly maintained in position while the head plank 78 is securely clamped by holding device 110. Such placement allows an operator to view an exposed portion 117 of a face plank 78 that is adjacent to but not covered by stationary plate 113, which allows the operator to view any potential defects on such exposed portion 117. In one embodiment, the exposed portion 117 corresponds to top plank face 119 (
In one embodiment, a user loads a head plank 78 into a first, receiving station 108X, such that an outer plank face 118 faces an outside of the turret 102 and an outer laser projector 111 (
In another embodiment, a user loads a head plank 78 into a first, receiving station 108X, such that an inner plank face 116 of the head plank 78 faces a laser projector 112, and an outer plank face 118 faces an outside of the turret 102 and an outer laser projector 111 (
In one embodiment, the laser projector 112 is a measuring laser device, also referred to as a “measuring eye.” In this embodiment, the laser projector 112 functions to measure or analyze and determine whether a tongue profile or a groove profile has been machined onto the inner plank face 116. If it is determined that a tongue joint has been machined onto the inner plank face 116, then a complimentary groove joint will be machined onto the outer plank face 118. However, if it is determined that a groove joint has been machined onto the inner plank face 116, then a complimentary tongue joint will be machined onto the outer plank face 118.
In one suitable embodiment, the user may visually inspect a surface of the head plank 78 that is determined to be an outside surface of the barrel 70. For example, the user may prefer for aesthetic or functionality reasons, that a particular side of the head plank 78 define the outside surface of barrel 70. Accordingly, the head plank 78 is positioned in the materials machining device 100 in a manner to ensure proper cuts are made in positions to allow the desired side of the head plank 78 to become part of the outer surface of barrel 70. Once the user is satisfied with the proper position of head plank 78 with respect to the projected laser cut lines 114, 115, the user may advance the head plank 78 to the next station by rotating turret 102, which may be rotated manually or using an automated motor or servo (not shown). In one suitable embodiment, the user activates the turret 102 via a manual actuator to rotate in a desired direction R to advance the head plank 78 to a next station. In a preferred embodiment, turret 102 is rotated in a direction R that is a counterclockwise direction. In the illustrated embodiment, for example, the user presses on a foot pedal (not shown) to selectively rotate the turret 102 but it is understood that any suitable manual actuator could be used. In other suitable embodiments, the materials machining device 100 may be automated such that the turret 102 automatically rotates to a next station once the head plank 78 has been properly positioned.
As illustrated in
In another embodiment, the head plank 78 may be held stationary, and the cutting machine 140 may be translated along the length of the face of the head plank 78 to cut the trim section 148 (shown in
The head plank is then manually or automatically advanced to jointing station 120 (
Depending on whether the user is cutting the first or second profile, the joint cutting wheel is positioned such that the proper profile is aligned with the plank face to be cut. The joint 130 may include one or more grooves 132, as best shown in
In the illustrated embodiment, the head plank 78 is held stationary, and the jointing machine 122 is translated along the length of the face of the head plank 78 to cut the joint 130 (shown in
In some embodiments, a sensor 126, such as 3-D video, laser, radar or mechanical touch sensor may be used to scan the joint that was cut by jointing machine 122. The data from the sensor 126 may be processed by a computer processor, which then provides a determination result to the user. Such determination result may indicate that the joint is cut to within tolerance or that the joint 130 is outside of a predetermined tolerance, and thus needs to be recut. In one suitable embodiment, the turret 102 rotates about the axis of rotation R in a counter-clockwise direction. In this embodiment, the sensor 126 scans the outer plank face 118 after having been cut by the cutting device 142 to determine whether a flatness of the outer plank face 118 is within a predetermined tolerance, or whether there are any other undesirable defects. In this embodiment, once it is determined that the outer plank face has no undesirable defects and that the flatness is within the predetermined tolerance, the head plank 78 is then moved to the jointing machine 122 to have the joint 130 cut thereon.
In the illustrated embodiment, after the joint 130 has been cut on one of the inner plank face 116 or the outer plank face 118 of head plank 78, the head plank may be removed from the holding device 110 at the first, receiving station 108X, flipped and reinserted into the holding device 110. In this embodiment, the head plank 78 is run back through the stations of the turret 102, including one or more of jointing station 120 and cutting station 140 to cut a second joint on the other one of inner face 116 and outer plank face 118 that was not previously cut. In such embodiment, a joint with the first profile is cut on one of inner plank face 116 or outer plank face 118, and a joint with the second profile is cut on the other one of inner plank face 116 or outer plank face 118. The joint is configured such that it is capable of interlocking with a joint of another head plank in a liquid tight manner. In another embodiment, a secondary jointing station, cutting station and sensor may be installed on an inside of turret 102, allowing inner plank face 116 to be processed in a manner similar to that of outer plank face 118, as described above, without being removed and re-installing the plank 78.
In one embodiment, inspections settings of the sensor 126 may be adjusted, such that the allowable margin of tolerance for passing an inspection is narrower or broader, depending on the user's desired outcome. In this embodiment, the sensor 126 and associated processor may be coupled to an input device, such as an electronic display and keyboard to allow the user to adjust the settings.
In another embodiment, once a joint 130 has been cut on one or both of inner plank face 116 and outer plank face 118, materials machining device 100 may output an alert to the user that the head plank 78 is complete and has passed inspection. Such alert may take the form of any visual or audio cue, such as a light or sound, that is sufficient to allow the user to know the head plank 78 has been satisfactorily machined.
In one embodiment, the materials machining apparatus 100 may include a sensor, such as sensor 126 that is configured to measure a length L of a head plank 78. If the length L is below a predetermined threshold, the head plank 78 is indicated to be a “cant” 150, 152. As used herein, the term “cant” refers to a plank that is too short, or has some other defect, such as a knot or other imperfection that makes it unsatisfactory to be used in an inner (i.e., middle) section of the end cap 84. If the plank is determined to be a cant 150, 152 then the user is alerted to such determination, and the cant 150, 152 will only have a joint 130 cut on one of inner plank face 116 or outer plank face 118, but not both. In one embodiment, the user may inspect the head plank 78 and make a determination as to whether the head plank 78 should be indicated to be a cant, and in this embodiment, the user presses a foot pedal, or other button, (not shown) to designate the plank as a cant. If the length L of a plank is determined to exceed a predetermined threshold, and no other material defect is present that would make the plank a cant, the plank is determined to be a middle plank 160, and will have a joint 130 cut on both of inner plank face 116 and outer plank face 118.
In one embodiment, a sufficient number of middle planks 160 and cants 150, 152 are cut by materials machining device 100 as described above, and press fit together such that a joint 130 of one head plank 78 fits a complementary joint of another head plank in a liquid-tight manner to form a blank 180, to exceed a diameter D of an end cap 84 (
In some embodiments, one or more safety sensors (not shown) may be present to detect whether a user's hands or other appendage is within a predetermined distance of the materials machining device 100. For example, one or more sensors may be used to determine whether the user's hands are in a safe position and/or confirm that the user's hands are clear of the turret 102. Suitable safety sensors are disclosed in U.S. Pat. No. 10,919,177, the contents of which are hereby incorporated by reference in its entirety. In this embodiment, the machine will not operate until such time the user has removed their hands or appendage to outside of the predetermined distance for which the sensor is calibrated. In such embodiment, the safety sensor may include a laser, infrared, radar, ultrasound or other sensor capable of allowing the safety sensor to operate as described herein. In another embodiment, a safety sensor may be used to detect whether the shield 812 is in its operating configurations, such that it is hinged down to cover port 802, and in this embodiment the machine will not operate until such time the shield is determined by the sensor to be in its operating configuration.
As used herein “manual” refers to those processes performed with direct intervention or action by a human operator. In contrast, “automatic” or “automated” refers to those processes performed under the direction of a computing device. Automatic processes may be configured and/or programmed by an operator and/or another user but are implemented under the direction of the computing device without human intervention.
The materials machining system described herein provides a number of advantages over known systems, such as increased throughput and higher-quality finished pieces (e.g., heads).
The present disclosure includes multiple embodiments, which include at least the following exemplary embodiments.
Embodiment 1. A device for machining material, comprising: a rotatable turret including a plurality of plank holding positions, each plank holding position including a plank holding device; a projector configured to project at least one cut line on a first surface of a plank; a cutting device positioned at a second location adjacent to the rotatable turret, the cutting device including a cutting tool configured to cut a trim section along a length of a second surface of the plank adjacent the first surface to establish a substantially planar portion of the second surface and/or remove one or more defects of the plank; a sensor configured to scan the second surface of the plank and determine whether the substantially planar portion is within a predetermined tolerance; and a jointing device positioned at a first location adjacent to the rotatable turret, the jointing device including a joint cutting tool configured to cut at least one groove at a location on the second surface.
Embodiment 2. The device according to Embodiment 1, wherein the plank holding device is a clamp.
Embodiment 3. The device according to any previous Embodiment, wherein the projector is a laser projector.
Embodiment 4. The device according to any previous Embodiment, wherein the projector is configured to project the at least one cut line along an entire length of the second surface of the plank.
Embodiment 5. The device according to any previous Embodiment, wherein the sensor is a 3-D video sensor.
Embodiment 6. The device according to any previous Embodiment, further comprising an alert configured to provide a visual or audio indication of whether the at least one groove and the substantially planar portion are within the predetermined tolerance.
Embodiment 7. The device according to any previous Embodiment, wherein at least one of the holding device and the cutting device are configured to translate to allow the trim section to be cut along an entire length of the second surface.
Embodiment 8. The device according to any previous Embodiment, wherein at least one of the holding device and the jointing device are configured to translate to allow the at least one groove to be cut along an entire length of the second surface.
Embodiment 9. The device according to any previous Embodiment, wherein the jointing device and the cutting device are located at an outside of the rotatable turret.
Embodiment 10. A method for machining material from a plank, comprising: placing a plank in one of a plurality of holding devices of a rotatable turret, wherein the turret has a plurality of discrete stations, each station including at least one of the holding devices; rotating the turret to position the plank at a projection station, the projection station including a projector; projecting at least one cut line on a first surface of the plank using the projector; rotating the turret to position the plank at a cutting station, the cutting station including a cutting device configured to cut a trim section from a second surface of the plank to form a substantially planar portion; rotating the turret to position the plank at a scanning station, the scanning station including a sensor configured to scan the second surface of the plank that is adjacent the first surface; using the scanner to determine whether the substantially planar portion is within a predetermined tolerance; rotating the turret to position the plank at a jointing station, the jointing station comprising a jointing device configured to cut at least one groove along the second surface of the plank; and cutting a groove in the second surface of the plank along a location of where the cut line was projected onto the first surface of the plank.
Embodiment 11. The method according to Embodiment 10, further comprising rotating a joint cutting wheel to cut the at least one groove.
Embodiment 12. The method according to any previous Embodiment, further comprising rotating a cutting wheel to cut the trim section from the second surface of the plank.
Embodiment 13. The method according to any previous Embodiment, wherein the plank is a wooden plank and the at least one groove is a portion of a tongue and groove joint.
Embodiment 14. The method according to any previous Embodiment, further comprising providing a visual or audio alert to a user of whether the substantially planar portion is within the predetermined tolerance.
Embodiment 15. The method according to any previous Embodiment, further comprising adjusting a position of the plank within the holding device after the at least one cut line is projected onto the first surface of the plank such that the at least one cut line does not project onto a defect of the plank.
Embodiment 16. The method according to any previous Embodiment, wherein the scanner is a 3-D video scanner.
Embodiment 17. The method according to any previous Embodiment, further comprising a user selecting the predetermined tolerance.
Embodiment 18. The method according to any previous Embodiment, wherein the sensor is used to determine a level of flatness and an absence of defects of the substantially planar portion of the plank.
Embodiment 19. The method according to any previous Embodiment, further comprising the sensor measuring a length of the plank and determining whether the plank is suitable for use as a middle piece or a cant piece.
Embodiment 20. The method according to any previous Embodiment, further comprising removing the plank and reinserting the plank in a second orientation into the holding device and projecting a second cut line on the first surface of the plank; cutting a trim section along a length of a third surface of the plank that is adjacent the first surface to establish a substantially planar portion of the third surface; scanning the third surface of the plank and determining whether the substantially planar portion of the third surface of the plank is within a predetermined tolerance; and cutting at least one groove on the third surface of the plank.
When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
This application claims priority to U.S. Provisional Patent Application No. 63/063,820, filed Aug. 10, 2020, the entire contents of which are hereby incorporated by reference.
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Entry |
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Extended European Search Report for Patent Application EP 21190375.2 dated Jan. 13, 2022; 8 pp. |
Number | Date | Country | |
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20220040880 A1 | Feb 2022 | US |
Number | Date | Country | |
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63063820 | Aug 2020 | US |