BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view of the automated molding cut-off saw according to a preferred embodiment.
FIG. 2 shows a block diagram of the typical method being used as prior art.
FIG. 3 shows a block diagram of the method of using the device according a preferred embodiment.
FIGS. 4A and 4B show screen shots from the input device or measurement tool.
FIG. 5 shows a detail view of the cut-off saw.
FIG. 6 shows an alternate embodiment of the molding cut-off saw using two saws.
DETAILED DESCRIPTION
FIG. 1 shows an isometric view of the automated molding cut-off saw 10 according to a preferred embodiment. This view shows the overall molding cutting machine with its various components. A detailed view showing the elements around the saw is found in FIG. 5. The saw 20 is a combination type saw where the angle and tilt of the blade is adjustable to match the requirements for making miter cuts to floor, wall and crown molding. It is contemplated that the saw and feeding mechanism is powered by one or multiple power sources including but not limited to wall supplied AC power, air and batteries. In this figure a rotary material dispensing apparatus 70 is shown for feeding material into the cutting portion or blade of the machine. While in this description, moldings are predominantly indicated, it is contemplated that the automatic saw in use with the data recording and transfer system is equally suited for use with metal, wood, plastic and other elongated materials.
In this embodiment the dispensing apparatus 70 has retaining means for retaining up to 12 lengths of material. The quantity of 12 provides a preferred number of holders to provide material for a single double or triple type built-up molding that might be found in different molding installations. The single, double and triple configuration of installed moldings is described in more detail with FIG. 4A. The dispensing apparatus 70 indexes with a motor or mechanism 72 to locate the desired material held in the apparatus at the height of the cutting surface. When the material is at the height of the cutting surface a pusher 74, pushes the material from the dispensing apparatus 70 onto the cutting table where it is gripped with locating and feeding wheels 40 that both measure the length of material that is being feed and push the material under and past the cutting blade 30. After a first cut, the material is indexed and measure for the second cut. The indexed material rolls over the table surface or on rollers 42 placed in the table surface. A marking apparatus that is shown and described in FIG. 5 marks or otherwise identifies each cut length. The operation continues for the second cut. The cut material is then pushed off the cutting table with pushers 50 and 55 into a collecting or wrapping bin 60. The bin 60 has slots 62 for bringing wrapping material around the items in the bin to keep then in a collective group.
Operation of the Cutting Machine
This operation of the cutting machine describes to operation for cutting of a single length of material. In normal operation the data of multiple cuts is collated to best use the material and minimize waste. Material is fed into the cutting machine from the dispensing apparatus 70 by pusher 74.
When the material is in the desired location clamps 45, located on one or both sides of the cutting blade 30, hold the molding material while it is being cut. In this configuration with a single cutting blade, the new length of molding material is fed into the cutting portion until the blade can make one or more a complete cut of the material. It is possible that between successive cuts that the material may be in the correct position or that the material may need to be slightly backed out of the cutting area. The material is clamped 45. The blade is rotated or tilted until it reaches the correct orientation. The blade 30 is started and passed through the molding material and returns to a position off of the molding. The clamp(s) 45 are released. The material is driven and measured with wheel(s) 40. As the material is being moved it passes by a printing, marking or other indicating apparatus (shown in FIG. 5) for identification of where the section of molding is to be placed.
When the material is in position for the next cut, the clamp(s) 45 hold the molding material. The blade is rotated or tilted until it reaches the correct orientation. The blade 30 is started and passed through the molding material and returns to a position off of the molding. The clamp(s) 45 are released. One or more pushers 50, 55 push the cut and marked material into bin 60. Scraps or remnants are either pushed off of the table as the length is pushed off the table, or is blown from under and around the blade.
It is also contemplated that the material be indexed finite positions between the two cuts and the blade brought partially through the molding to provide one or more kerfs to make bending that wood easier. In a further contemplated operation, the material is indexed to one or more specific positions where the blade removes some material from the molding to provide clearance or an anomaly along the wall or for clearance of wires, pipes or similar features. It is further contemplated that the material is visually inspected as it is being fed under the saw and defects or Imperfections in the material are cut around or discarded.
FIG. 2 shows a block diagram of the typical method being used as prior art. This method will be described in brevity to provide understanding of the current method and the benefits associated with the proposed molding cutting system. The operation is generally performed by one person with one or more helpers and the measurement and cutting involves primarily accurate measurements, but some art and experience is involved, especially where difficult corners or miters are involved. Each wall is first measured 100. The measurements are recorded, usually on paper. The person measuring may alternatively make a sketch of the room or use architectural drawings where they enter the actual lengths of each room 102. The measurements are then taken to a miter saw where the blade is set to a first cut 104. In a simple room requiring only floor molding with square miter corners only two opposed 45 degree angle cuts are required. In a more complex installation with triple-crown molding, bull nose edges, and some walls that are not 90 degree angles, a large number of different angular cuts are required, each with different angle settings.
The length 106 of the molding is marked on the molding and the blade angle is set. Newer compound miter cutting saws incorporate a laser with the cutting blade making it easier to determine where the kerf of the blade will be made prior to making the cut. The angle and or miter are manually set on the saw 108 and the piece of molding is cut at the indicated length 108. This operation continues where the blade is set to a first angle, the part is cut, measured, and the blade is set to second angle and cut again until a group of parts are cut, or each part is individually cut and moved to the room 110 where it is located 112 in order. The moldings are then installed and nailed in place 114. While only one cut per side of the molding is disclosed, it is contemplated that multiple cuts can be made to each end of the molding.
FIG. 3 shows a block diagram of the method of using the device according a preferred embodiment. One or more workers can work independently in different rooms 120 and 122. The measurements and cuts are entered into an input device that Is shown and described in more detail with FIGS. 4A and 4B. The information is transmitted to the automatic molding cutting machine that collates the cuts 130 determines the optimal order to cut the material for the best utilization. When a sufficient amount of cuts is entered or all measurements are entered for the material, the machine automatically loads the material, sorts the cuts, cuts the parts, and marks the parts 140. The person that measured the room can move the moldings to the designated room, or an unskilled apprentice worker can move the material and place the parts around the room based upon the identification on each part 170. The parts are then set and-nailed in position. The advantage is in setting the saw for the various cutting angles, marking the parts for accurate placement in a specific room, and efficient utilization of the lengths of moldings. The speed and repeatability of setting the angles and measuring the lengths is greatly improved, as well as the ability to complete installation in a reduced period of time.
FIGS. 4A and 4B show screen shots from the input device or measurement tool. These screen shots show some contemplated display and selection information. These are screens that appear on a PDA with wireless or wired connectability to transmit data to the cutting station. They could also appear on a cell phone, or be integrated into a tape measure, or ultrasonic measuring tool. The input can have a voice entry of the data as measurements are taken, and further provide an audible announcing of the measurement to confirm the entered data. In FIG. 4A the user visually sees the information on the screen 200 and selects with keys, stylus or finger the type of job. The specific location or room, in this case Room 123, 210 is entered. Additional information or alternative information can also be visible such as “bedroom”, “living room” or other such designation. The type of installation is for crown molding 220, but the other options for floor, and wall molding is also shown as available. Since crown molding was selected, three types of crown molding is available, single 230, double 232 and triple 234 with a graphic showing the installation type. The user has selected a double 232 for the installation. When the molding is being cut by the machine, it will cut separately both the backer and the crown section for each wall, and will account for the thickness of the backer in corners automatically based upon the thickness parameters for the backer(s).
With the type of installation selected, a small diagram 300 will allow the user to enter or measure the distance along with designation of the part being used for an inside miter corner wall B-C or an outside miter corner wall A-B. The room 123 (210) is still shown to reduce the possibility of confusion for measurements and cuttings. In this screen shown, an outside miter corner wall A-B is shown selected 310. The wall corners are selected a square 312 as opposed to bull nose that usually requires an extra molding piece on outer miter corners. The length of wall A_B is entered, or if the input device is integrated in a tape measure, the tape measure is extended to the length of the wall 314, and an enter button is selected so the measurement is stored. The operator can then select another length or wall 316, or they can select another room 318. The input device can compare measurements from similar rooms to check for errors and or prompt for similar measurements. The data is transferred to the cutting machine either one measurement at a time or as a collective room when all measurements are taken. All the measurements can further be downloaded into a computer for additional analysis, billing or material purchasing.
FIG. 5 shows a detail view of the cut-off saw 20. Material is fed 41 into the drive/measurement wheels 40 where it slides 43 on the table 12. The blade 30 is adjusted for miter 24 of the blade 30 and or the compound miter cut angle 28. The molding material is moved until it sufficiently enters to ensure a complete cut of the material. The material is clamped with clamps 45 and or 47 that move down or in 46 and 48 to hold the parts while they are being cut. The blade 30 is rotated 22, and the blade is brought to cut through the molding. A slot 21 provides clearance for the blade to pass completely through the molding. While this operation of feeding, angular adjustment and cutting is automatically performed, a manual handle 23 is provided to allow for manual operation of the cutting to account for minor cutting, trimming or fitting of some pieces if required.
Indicating apparatus 80 prints, marks or otherwise places identification of where the section of molding is to be placed. In one contemplated embodiment the marking sprays ink onto the molding as it moves past the indicating apparatus. Ink or paint has the advantage of being wiped off or painted over, and can be placed on any side of the material. Ink has the disadvantage of clogging in the intended environment and must be filled. In the preferred embodiment the marking is with printing heads or pins that inscribe information into the material as it passes the indicating apparatus. This method of marking has the advantage of not requiring any ink and is permanent with the exception of sanding the mark off the molding. It has the disadvantage that it should only be applied to a non-cosmetic surface. Subsequent cuts are preformed in the same or similar manner as previously described until the part is cut free from the length of molding material. The finished and marked length is then pushed 52 with one or more pushers 50 that moves the material off the cutting table 12 and into a tray that is shown and descried in FIGS. 1 and 6.
FIG. 6 shows an alternate embodiment of the molding cut-off saw 10 using two saws 20 and 23. The components used in the two saw configuration are similar to the components previously described with the exception of a second cutting station 23 having a second blade 35 that in addition to adjusting angle and miter, the cutter translates 14 on the table allowing both ends of the material to be cut at the same time. The dispensing apparatus 70 indexes with a motor or mechanism 72 to locate the desired material held in the apparatus at the height of the cutting surface. When the material is at the height of the cutting surface a pusher 74, pushes the material from the dispensing apparatus 70 onto the cutting table where it is gripped by wheels 40. Locating and feeding wheels 40 both measure the length of material that is being feed and push the material under and past the cutting blade 30.
The material rolls over the table surface or on rollers 42 placed in the table surface. A marking apparatus that is shown and described in FIG. 5 marks or otherwise identifies each cut length. When the material is in position the material is clamed 45 and cut with the two saws. The cut material is then pushed off the cutting table with pushers 50 and 55 into a collecting or wrapping bin 60. The bin 60 has slots 62 for bringing wrapping material around the items in the bin to keep then in a collective group.
Thus, specific embodiments of an automated molding cut-off saw and method have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.
Patent Application
20080034934
