The present invention relates to processing wood products, and in particular to apparatus and a method for feeding flitches into an edger so as to optimize production of marketable lumber from the flitches.
When a log is sawed in the process of producing lumber a cant or cants are produced from the central portion of the log by removing slabs and flitches from sides of the log, usually in a way to maximize the marketable amount of lumber that can be produced from the cants. Flitches removed from the sides of the log may include wane that can be removed by an edger to obtain marketable lumber from each flitch.
An edger typically includes several parallel circular saw blades spaced at standard distances, or in some cases adjustably spaced, along an arbor. Sets of powered bottom rollers and press rollers are arranged to run a flitch longitudinally through the edger saws to produce standard-sized boards and remove edge portions that have no commercial value as lumber.
In conventional practice, an edger operator manually places each flitch onto infeed rollers of an edger in a position estimated to provide the maximum amount of marketable lumber from a particular flitch, in some cases with the assistance of laser guidelines. In such conventional edger operation flitches are delivered serially and longitudinally into a preliminary position where the edger operator must adjust its position and orientation before edger infeed rollers pinch the flitch and deliver it into the saw blades. As a result, there is a significant gap between the tail end of a flitch being sawn in the edger and the head end of the next flitch to enter the edger saw blades.
As a result of the gaps between flitches being fed into an edger, there may be a significant delay, or dead time, of as much as a few seconds between flitches going through an edger. The output of an edger could be significantly increased by reducing the space between the tail of one flitch and the head end of the next flitch, thus reducing the dead time between successive flitches.
What is desired, then, is a way to reduce the dead time between flitches being sent through an edger, and at the same time to maximize the production of marketable lumber from flitches by ensuring that they are located and oriented, as they pass through an edger, so as to produce boards calculated to result in the maximum value of marketable boards from each flitch.
As an answer to some of the needs explained above, an edger feeding apparatus and a method of feeding flitches into an edger with only a minimum spacing and dead time between successive flitches are disclosed hereinbelow and defined in the claims that form a part of the disclosure.
In one embodiment of the apparatus disclosed herein, a feed line, also called a scanner and carriage assembly, moves individual flitches laterally, in a direction transverse to the length of each flitch, and a scanning system associated with the feed line measures each flitch and creates and stores a digital three-dimensional model of each flitch. The flitches are moved to a transfer ready position at an outfeed end of the scanner and carriage assembly in readiness to be transferred laterally to an edger ready position near the infeed end of an edger and a small distance above the edger infeed mechanism. Transfer of successive flitches to the edger infeed mechanism is accomplished in a much shorter time than by moving each flitch longitudinally after another.
In one embodiment of the apparatus, a control computer keeps the digital models of the flitches in memory in a queue specifically identifying the three-dimensional model of each flitch. Based on, for example, tabulations of the commercial values of different sizes and qualities of boards, the control computer determines how each flitch should be located and oriented on the edger infeed mechanism as it proceeds longitudinally through the edger, to produce the most valuable yield of lumber from that flitch.
In one embodiment of the apparatus, each flitch is stopped in a transfer ready holding position and then is engaged to be moved by a charger subassembly. Each charger subassembly includes a lower flitch carrier member spaced apart from another along the length of the flitch, and each flitch carrier member includes a turntable portion which can engage the bottom of the flitch. A respective upper contact pad is moved down by an actuator to press the flitch onto the turntable portion of the flitch carrier member. The upper contact pad is positioned located directly above the turntable portion of the flitch carrier member. The flitch carriers are moved to carry the flitch laterally to the edger ready position, in a desired location and orientation above the edger infeed mechanism in a very short time. Each of the upper contact pads is controlled to move together with and remain aligned with the turntable of its corresponding flitch carrier member as the feed forks and contact pads move the flitch to the desired edger ready position with respect to an infeed mechanism of the edger that will result in the maximum commercial value of the boards that can be obtained from that flitch.
For example, an edge portion may be removed from each edge of a flitch, leaving a single dimensional board with four flat sides. For another flitch the control computer may direct the feed forks to orient and position the flitch where the edger will produce one board with four flat sides and another, lower grade, board with one edge surface including acceptable wane, depending upon the shape of the digital model of the flitch that has been produced by the control computer as result of scanning the flitch. Yet another flitch may be oriented and positioned so that when it proceeds through the edger two boards with acceptable wane will be produced.
In one embodiment of the apparatus, when a flitch is positioned above the infeed mechanism, a set of tipples adjacent the infeed mechanism are moved upward and into supporting contact with the underside of the flitch. At the same time, an infeed press roller associated with a tipple is lowered into contact with the upper side of the flitch, so the flitch is held in the correct location. Once the flitch has been grasped and is held by the tipples and the press rollers the flitch carrier members and the upper contact pads release the flitch and are retracted. The infeed press rollers keep the flitch in the desired orientation and location established by the carrier members and pressure pads and in contact with and supported by the tipples.
Once a preceding flitch has been moved far enough toward the edger saws the tipples are lowered and the accompanying infeed press rollers are raised, moving the flitch in the direction of movement of the infeed mechanism and lowering the flitch onto the infeed mechanism. In one embodiment of the invention the control computer takes into account the time that may be required to adjust the positions of the edger saw blades after the preceding flitch has cleared, while the flitch is supported and held by the tipples and press roller. The flitch is then lowered onto the edger infeed mechanism at a calculated time and in a controlled fashion so as to come into contact with the edger infeed mechanism in the position and orientation that has been calculated by the control computer to result in producing boards of optimum value from that flitch.
In accordance with one aspect of a method disclosed herein, then, each of a series of flitches is scanned, a queue of three-dimensional models is produced, and the control computer calculates a position and an orientation for each flitch so as to feed the flitch into the edger and thus produce the optimal yield of lumber from the flitch. When a flitch reaches the final position on the feedline, or scanner and carriage assembly, where it is the next in line to be sent through the edger, it is moved by the flitch carrier members to a predetermined orientation and position above the edger infeed mechanism. When a preceding flitch has moved out of the way the flitch is engaged by tipples and pressure rollers and the flitch carrier members are retracted.
After a preceding flitch has moved a calculated distance toward the edger saws the flitch may be lowered onto the edger infeed chain and moved to where it can be engaged by infeed rollers of the edger. If the flitch is to be sawn into a different number of boards or into boards of widths or locations within the flitch that are different from the preceding flitch the amount of time required to adjust the edger saws is taken into account in determining when to move the flitch from the ready position to be engaged by the edger infeed mechanism.
The foregoing and other objectives and features of the invention will be more readily understood upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings.
Referring first to
A scanner and carriage assembly 32, that also may be called a feedline, has a structural frame 34 oriented to deliver flitches 24, 26, etc. to the edger 20 by moving each flitch laterally, that is, in the direction of the arrow 36, perpendicular to the length 38 of each flitch 24, 26, etc. The flitches are arranged side-by-side, lying flat and with their lengths oriented generally parallel with the arrow 40, indicating the direction in the direction of which each flitch will pass longitudinally through the edger 20. An end of each flitch that will be the leading end 41 as the flitch enters the edger is aligned with a lumber line 42, at the right-hand end of the scanner and carriage assembly 32 as seen in
Depending upon the amount of manual labor that will be acceptable, the scanner and carriage assembly 32 may include a scanner (not shown) capable of discovering whether a wane side of a flitch is up or down. A flitch turning mechanism 46 mentioned in
The frame 34 of the feed chain or scanner and carriage 32 assembly or scanner and carriage 30 includes a group of feed rail assemblies 50 that are oriented horizontally and parallel with each other, separated from one another by a distance 52 that is somewhat less than the length of the shortest flitch intended to be fed to the edger 20. For example, the feed rail assemblies 50 may be spaced apart from each other by a distance corresponding to a standard board length intended to be produced. As shown in
Endless loop feed chains 54 of which there are four shown in
Six sets of hooks 60, seen in
As may be seen in
The arms 62 carrying the ones of a set of hooks 60 may all be mounted on a shaft 64 extending transversely of the scanner and carriage, or feed line, assembly, thus parallel with the length of a flitch on the scanner and carriage assembly. Each such shaft 64 may be rotated through a few degrees in either direction by a respective lever 66 that is moved in either direction by suitable means such as inflation and deflation of the ones of a respective pair of airbags 68, for example, as may be seen in
The flitch measuring scanner system 44, not shown in detail, is supported on a scanner support structure 70 extending above the scanner and carriage assembly 32. The scanner support structure 70 is long enough to permit passage of the longest flitch intended to be handled by the edger infeed mechanism. The scanner system 44 may include a scanner array 72 of several laser scanners, and is located between hook stop #4 and hook stop #5 along the scanner and carriage assembly 32, where each flitch 24, 26, etc. can be scanned precisely as it is carried along the feed rail assemblies 50 by the feed chains 54. The scanner array 72 may, for example, measure a flitch on a grid of points spaced at 0.035″×0.035″ separation on all surfaces of the flitch. The scanner array 72 is connected functionally to a control computer 74, as shown in
The control computer 74 is adapted to receive the digital data from the scanner array 72 and to compile it as a digital three-dimensional model, such as a wireframe model, of each flitch. The three-dimensional model of a flitch may preferably be prepared to a resolution of 0.001 inch, to identify the boundaries of the flat upper face of each flitch, where the flitch begins to wane, and the control computer 74 utilizes the digital three-dimensional model as a basis for deciding what parts of the flitch should be removed by the edger 20. An optimizer section 76 of the control computer 74 incorporates a database which may include a tabulation of many different sizes, types, and grades of lumber and the current value of each. The control computer 74 may be programmed to determine from the three-dimensional model what boards of which grades can be produced from a particular flitch 24, for example, which parts of the flitch should be removed by the edger and how to cut the remaining portion of the flitch into pieces which can result in an optimum value of marketable lumber. A sawing solution is then developed by the control computer 74 and conforming instructions and data may be communicated among the various elements of the edger 20, the scanner and carriage assembly 32, and the edger feed mechanism 22 using a programmable logic controller 77 so that the flitch will be sawed accordingly by the edger 20. The sawing solution may include instructions to require the edger to adjust the positions of individual ones of the various saw blades.
The digital three-dimensional flitch models are retained in digital memory by the control computer 74, and are coordinated with data from the feed chains 54, making three-dimensional model of each flitch 24, 26, 28, or 30, etc. the size and shape of each flitch available for use by the control computer 74 when the flitch reaches a transfer ready position 78, in hook stop #6, at the outfeed end of the scanner and carriage, or feedline, assembly 32.
A charger assembly 88 is located at the outfeed end of the scanner and carriage assembly 32 to transfer each flitch to an edger infeed mechanism. The charger assembly includes a charger subassembly 82, 84, 86, and 88, each conveniently associated with one of the feed chains 54. The charger subassemblies for convenience will be called charger sets numbers 1, 2, 3, and 4, as seen in right-to-left order in
Each of the elongate charger lower support members 94 desirably has a portion 104 near its outer end that may be called a turntable. The turntable 104 may be a set of concentric circular ridges extending proud of the surrounding surface of the respective lower charger member with a height of, for example, 0.020 inch, that will provide a reasonably secure grip on a bottom face of a flitch, without noticeably marring the surface of the wood. With a charger lower flitch support member 94 in the retracted position, a flitch 24, etc. in the transfer ready location 78 at hook stop #6 is directly above the turntable of the feed fork.
An upper charger support structure 106 that is part of each charger set 82 or 84, etc. extends toward the scanner and carriage assembly 32 from a support frame structure at a rear side of the edger infeed assembly 22. An endless belt 108 extends horizontally along the upper charger support structure 106, looped around a sprocket 110 at an outer end of the upper support charger structure 106 and a drive sprocket 112 mounted on a clamp pad positioning servo motor 114 at an inner end of the upper support frame structure. A clamp pad actuator 116 that may be an air cylinder-and-piston assembly is mounted on a slide track 118 extending horizontally along the upper support structure 106. The clamp pad actuator 116 is connected with the endless belt 108 so that the clamp pad servo motor 114 controls its position along the slide track 118 under the control of the computer 74 with the same degree of precision by which the lower charger flitch carrier member 94 is controlled, so as to keep the actuator 116 located above the turntable 104. A clamp pad 120 is carried on a moveable member of the clamp pad actuator 116, and is thus kept directly above the center of the turntable 104. The clamp pad 120 is arranged to move vertically so as to press a flitch 24, 26, etc. down onto the turntable 104 of the lower flitch support member 94. It will be understood that either an air cylinder or another convenient type of motor such as an electric actuator or a hydraulic cylinder-and-piston assembly could be used as the clamp pad actuator 116.
The lower charger beam 90 of each charger set 82, 84, etc. can be moved through a small angle about its pivot 92, by a motor 122 such as an air cylinder and piston mounted on the frame of the scanner and carriage assembly and linked to an outer end of the beam 90. By lowering the outer end of the beam 90, the outer end of the charger lower flitch support member 94 can be lowered a small distance, for example about ½ inch, to be clear of the bottom face of a flitch 24, 26, etc. in the transfer ready position 78 at the outfeed end of the scanner and carriage assembly 32 until the turntable 104 and clamp pad 120 of the charger set 82, etc. is in a required position and is intended to engage the flitch at the middle 123 of its width. When the charger set 82, etc. is correctly located the motor 122 can raise the outer end of the lower flitch support member 94, bringing its turntable 104 into contact with the flitch that is ready to be transferred. At the same or shortly later time the clamp pad 120 can be lowered against the upper face of the flitch.
The edger infeed mechanism 22 may include an endless edger infeed chain 124 arranged as a loop around suitable sprockets, a drive sprocket 126 and an idler sprocket 128, and driven continuously in a vertical plane perpendicular to the infeed chains of the scanner and carriage assembly 32 so as to carry a flitch 24, etc. longitudinally into the edger 20. An upper run 130 of the edger infeed chain 124 may extend along and ride upon a suitable horizontal support rail 132. The edger feed chain 124 may be a roller chain with the outer edges of the side plates of each link having a sawtooth shape, as shown in the inset in
A respective tipple 134 is associated with each of the charger sets 82, 84, 86, and 88, and each tipple will be referred to separately by the member of the charger set with which it as associated. Each tipple is mounted on a respective tipple shaft 136 extending horizontally and perpendicular to the plane of the edger infeed chain 124 and thus parallel with the direction of movement of flitches along the scanner and carriage assembly 32. The tipples 134 may be generally planar, extending radially outwardly away from the respective tipple shafts 136. The tipples 134 have outer margins 138 that may have roughened or textured surfaces intended to engage a bottom face of a flitch frictionally.
A respective infeed press roller 140 may be mounted for rotation about the axis perpendicular in the place of the sharpchain 124 and may be carried on a support arm 142 attached to each of the upper charger support beams 106 on its upstream side, further from the edger 20 and opposite the location of the associated clamp pad actuator 116. The support arm 142 may be arranged to pivot up and down about a horizontal pivot axis 144 that may also be perpendicular to the plane of the edger infeed sharpchain 124. A suitable motor 146 such as an air cylinder-and-piston assembly is arranged to raise and lower the edger infeed press roller 140 to press a flitch 24, etc. down against a tipple 134 in the edger ready position and also while lowering the flitch onto the upper 130 of the sharpchain 124, and then to keep the flitch in contact with the sharpchain 124 as the flitch is delivered into the edger 20.
The tipple shafts 136 are located beneath the infeed press rollers 140, allowing each of the tipples 134 to be rotated, between a lowered position as seen in
Suitable sensors such as photocells 152, 154 may be located respectively a short distance upstream from each of the #1 tipple and the #2 tipple, in positions enabling the sensors to recognize that a tail end 162 of a flitch is passing the respective one of the tipples 134.
Under digital control from the control computer 74, each lower flitch carrier servo motor 102 and the associated clamp pad actuator positioning servo motor 114 are operated synchronously to move a respective end of a flitch 24, etc. from the transfer ready position 78 over a distance determined by the control computer 74 on the basis of the digital three-dimensional model of the particular flitch. A flitch thus can be moved from the transfer ready location 78 toward a calculated edger ready position 156 directly above the sharpchain 124 of the edger infeed mechanism 22. As shown in
The sequence of steps for carrying flitches through the edger feed apparatus and the edger is shown in a flow chart embodied in
When the hooks of hook stop #4 are lowered the feed chains 54 carry the flitch through the scanner support structure 70, and the upper and lower scanner arrays 72 measure the flitch and transmits scanner data to the control computer 74, enabling the control computer to generate the digital three-dimensional model of the flitch. When the flitch just scanned reaches hook stop #5 the flitch is retained until a preceding flitch at hook stop #6 has been engaged by the charger mechanism 80 and is being transferred toward the edger ready position 156. When the charger mechanism 80 has carried a proceeding flitch clearly away from the transfer ready position at hook stop #6 the hooks of hook stop #6 are raised to stop the flitch being moved from hook stop #5 in the transfer ready position in hook stop #6 at the outfeed end of the scanner and carriage assembly as shown in
The feed chains 54 thus eventually carry each flitch 24, 26, etc. to the transfer ready position 78 at an outfeed end of the scanner and carriage assembly 32 at hook stop #6, where a charger assembly receives the flitch and moves it to the edger ready location 156 above an edger infeed mechanism 22 arranged to carry the flitch into the edger 20.
In the transfer ready position 78, the desired set of hooks 60 of hook stop #6 stop the flitch 24 and establish a full taper orientation, located where the flitch can be grasped to be moved to the desired orientation in the edger ready position and location 156 from which it is to be moved onto the edger infeed mechanism 22. With the flitch in the transfer ready location 78, at least a pair of the elongate charger lower flitch support members 94, are located beneath the flitch in a retracted position along the slide track on the beam 90.
When the flitch 24 has arrived at hook stop #6 it is ready for the charging sequence to be performed as directed by the control computer 74. This begins as shown in
When a previous flitch has been carried on the sharpchain 124 far enough into the edger 20 for press rollers 121 within the edger 20 to grip the previous flitch, the press rollers 140 of the charger sets #2, #3, and #4 are raised (step 4). When the tail end 162 is detected passing a sensor such as photocell 152 at the #1 charger set 82 the infeed press roller 140 at the #1 charger set 82 is raised, providing clearance above the sharpchain 124 to receive the flitch 24 being supported by the charger sets 82 and 88 at the transfer ready location. While the press rollers 140 are being raised the charger sets are briefly held (step 5) before moving the flitch 24 to the edger ready position 156.
When the space above the tipples 134 is cleared the two engaged charger sets may move by slightly different distances away from the transfer ready location 78 and toward the opposite side of the edger infeed mechanism 22, moving the flitch 24 to the edger ready position 156 above the sharpchain 124 of the edger infeed mechanism in which the desired saw cut lines are parallel with the sharpchain 124 and where the flitch is offset laterally as necessary to rest in an optimal transport position on the sharpchain (step 6).
As the flitch 24 moves clear of the transfer ready position 78 the hooks 60 of hook stop #6 are raised (step 7). When a flitch 24 has been carried by the lower flitch carrier members to the edger ready position in the calculated location and orientation above the sharpchain 124 of the edger infeed mechanism 22 it is held there until a preceding flitch has been moved far enough into the edger 20 so that none of the preceding flitch remains above any of a set of tipples 134, as in
Once the flitch 24 is supported by the tipples 134, the lower charger beam actuator 122 is retracted to lower the lower flitch carrier members 94 a small distance from the lower face of the flitch, and the hold down pads 120 are raised from the upper face of the flitch (step 11). The flitch carrier motors 102 and hold down clamp pad carrier motors 114 are then operated to retract the lower flitch carrier members and move the clamp pad actuator 116 toward the transfer ready position 78 so as to be clear of the flitch 24 and ready to engage the flitch 26 when it is moved into the transfer ready position by the next cycle of the scanner and carriage assembly 32 (steps 12, 13).
The flitch 24 is then held between the tipples 134 and the edger infeed press rollers 140 as shown in
Once the charger lower flitch support members 94 and clamp pad 120 and their actuators 116 have moved away from the flitch 24 the tipples 134 are not obstructed and are clear to be rotated downward. When the sawing solution for the flitch 24 being moved laterally into the upper edger ready position 156 calls for it to be sawn by the edger 20 into the same number and sizes of boards as the immediately preceding flitch, very little time is required for adjustment of the positions of the edger saw blades by the servo motors 160 as directed by the control computer 74 as shown in
As may be seen in
As the tipples 134 are rotated downward the infeed press rollers 140 are also moved downward, remaining in contact with the top face of the flitch 124 and pressing the flitch first against the outer margins 138 of the tipples and then against the upper edges of the sharpchain. The sharpchain 124 then carries the flitch toward the edger 20, feeding the leading end of the flitch between the edger press rolls 121 which then engage the flitch and move it through the saws to cut the flitch into boards according to the optimal sawing solution that was generated by the control computer 74 prior to operation of the charger mechanism.
After the calculated amount of movement of the tail end 162 of the previous flitch beyond the tipples, allowing for repositioning of the edger saws as mentioned above, the tipples 134 are lowered and the flitch 24 descends down upon the edger infeed sharpchain 124 and is pressed downward against the edger infeed sharpchain 124 by the infeed press rollers 140. The edger infeed sharpchain 124 then carries the flitch 24 toward the edger 20. Referring now to
By the time the flitch 24 has been moved far enough into the edger 20 and is being moved through the saws 31 by the feed rolls 121 of the edger 20 far enough so that the tail end of the flitch 24 has moved beyond the #1 tipple, the tipple 134 closest to the edger 20, the following flitch 26 should have been carried by the lower flitch carrier members 94 and clamp pads 120 into the edger ready position 156, so that the cycle can be repeated as subsequent flitches 28, 30 etc. are moved laterally through the series of hook stops, and are scanned and converted into three-dimensional models and saved in the memory of the control computer 74, together with the data necessary to each flitch to the edger ready position and ultimately through the edger 20.
Once the preceding flitch has cleared the tipples and the leading end 41 of the flitch 24 is supported by the tipples 134, when the tipples are lowered the flitch 24 supported by the tipples is already positioned to be fed to the edger saw blades 31 in the most advantageous position and orientation. The flitch has only to drop a small distance, such as about 4 inches, from the edger ready position 156 once the tail end 162 of the preceding flitch is clear from beneath the leading end 41 of the flitch 24 supported by the tipples. Lowering the tipples 134, with the edger infeed presser rollers 140 pushing down on the top of the flitch, accelerates the flitch toward the edger saw blades 31, bringing it to a speed approaching that of the edger infeed sharpchain 124. The tipples 134 and the edger infeed presser rollers 140 continue to positively grasp and hold the flitch 24 until the flitch-contacting surfaces 138 of the tipples 134 have been lowered beneath the level of the upper faces of the edger infeed sharpchain 124. The edger infeed sharpchain 124 then engages and moves the flitch toward the edger press rollers 121. This transfer of the flitch 24 from the infeed scanner and carriage assembly 32 to the edger infeed sharpchain 124 and the change of direction from lateral movement to longitudinal movement of the flitch can all occur within a very brief time, as shown in
Each time division on the time axis in
During the entire cycle 184 a flitch transfer charging cycle 186, the complete set of actions for transfer of a flitch in a lateral direction from the scanner and carriage assembly 32 to the charger ready position 156, may be completed in less than one second. After necessary delay while a preceding flitch clears the edger infeed mechanism 22 and enough space is left behind the tail end 162 of the preceding flitch for the preceding flitch to be clear of the saws 31 of the edger 20 and the saw blade positions are adjusted, before the next flitch engages the saw blades 31. In a complete sharpchain loading cycle 188 each flitch can be lowered from the edger ready position 156 onto the edger feed sharpchain 124 and delivered into the edger 20 far enough to be engaged by the second feed press rollers 121 in slightly more than 0.6 second.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
This application is a continuation of U.S. Non-Provisional patent application Ser. No. 16/438,005 filed on Jun. 11, 2019 and entitled “METHOD AND APPARATUS FOR FEEDING AN EDGER.” which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/683,509 filed on Jun. 11, 2018 and entitled “METHOD AND APPARATUS FOR FEEDING AN EDGER.” The complete disclosures of the above applications are hereby incorporated by all reference for all purposes.
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20220184842 A1 | Jun 2022 | US |
Number | Date | Country | |
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62683509 | Jun 2018 | US |
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Parent | 16438005 | Jun 2019 | US |
Child | 17688046 | US |