Patent Application
20070006970
The present invention relates to a panel edge modification device or unit for a contour edge banding device.
In particular although not solely the present invention relates to a trimming unit which is or can be incorporated with an edge banding aggregate in a contour banding application such as is commonly utilised for the manufacturing of furniture including, for example, table tops.
When edge tape is applied to panels, the edge tape is normally wider than the edge to which it is being applied so as to allow for variations in thickness of the panel and the variations in alignment when applying the tape. In prior art edge banding equipment the tape is first applied to the edge in a first pass of a first machine followed by the trimming of the tape top and bottom to make it flush with the panel surfaces which occurs in a separate process to the process of applying the tape to the edge of the panel. An example of an existing apparatus which can be used for the application of edge tape to an edge of a panel is, for example, shown in our PCT application WO 02/14033, the entire contents is hereby incorporated by way of reference as part of this patent specification.
It would be desirable in order to reduce processing time for the same pass of tooling used to apply the tape to the edge of a panel, that a trimming process simultaneously occurs.
Previous edge banding equipment used in contoured panel applications have not provided for a one step application and trimming process. Current machines are mostly CNC controlled and edge banding is able to be applied by the positioning of a pressure roller in accordance to a pre programmed route or locus. The control of a trimming device from the same structure as the application roller can cause complications. The pressure roller and a trimming blade would need to be spaced apart sufficient to allow the tape adhesive to at least in part dry and to avoid fouling. CNC devices are position controlled by active servos. The additional incorporation and CNC control of a trimmer which is spatially separated from the pressure roller location would make for a very complex device where pre-programming of two positioning factors need to be taken into consideration, i.e. the roller and the trimmer. An example of current machines is as those exemplified in DE3517194, DE3702154, EP945235 and EP0728561. Other forms of modification of an edge of a panel may also be required. Accordingly whilst herein reference is made to the present invention in relation to the cutting or trimming of edge applied tape, it will be appreciated that the cutting device utilised may alternatively be substitutive by other units capable of for example performing a sanding operation, scraping operation or foil wrapping operation.
Accordingly it is an object of the present invention to provide a panel edge modification device or unit for a contour edge banding device which achieves the abovementioned desiderata or which will at least provide the public with a useful choice.
The present invention relates to a mechanism which allows suspending of a trimming unit off the same aggregate as that which applies the tape to the edge of a panel. The trimming operation follows immediately behind the tape applicator and trims the tape flush in one pass.
Accordingly in a first aspect the present invention consists in an edge banding apparatus for the application of an edge tape to at least part of an edge of a substantially planar panel said edge defining a perimeter of said panel of an arbitrary profile, said apparatus comprising:
a means to mount said panel on a fixed structure
an edge follower including at least one edge contact roller to follow at least part of the perimeter of said panel
an edge follower support structure to allow displacement of said edge follower relative to said fixed structure and when in use, relative to a said panel
an edge sensor capable of determining the slope, of said profile of said panel at where said edge follower is engaged to said panel, relative to a fixed frame of reference
force application means to apply a vectored force to said edge follower to bias said at least one contact roller toward the edge of said panel, said force application means capable of vectoring the force applied to said edge follower relative to said fixed frame of reference and in response to the shape determined from said edge sensor, in a manner to vector the resultant force to said edge follower in a direction
a) to bias said at least one contact roller towards said edge and
b) substantially not along said edge (save for optionally a very small component in or against the direction of travel of said edge follower along said profile)
means to generate relative movement between said edge follower and said planar object to thereby induce movement of said edge follower along at least part of the profile,
wherein said edge follower includes a tape feeding means which allows for the feeding of tape onto the edge of said panel at where said contact roller is biased towards said panel to, in use, press said tape onto the edge of said panel, and
wherein a trailing tape modifying unit is dependent from the edge follower by an arm pivotable about an axis parallel to the normal of the major surfaces of said panel, said modifying unit biased towards the panel when in use, in order to remain in contact with said panel, said modifying unit including at least one tape modifying means and at least one guiding means for guiding movement of said modifying unit relative to said panel.
Preferably said modifying unit is a trimming unit including a said modifying means to apply a trimming action to any panel major surface protruding tape adjacent at least one and preferably both major surfaces of said panel.
Preferably said modifying means is a device being one or more selected from at least one of (a) a rotary cutter (b) a rotary sander (c) a rotary grinder.
Preferably said device is a rotary device having an axis of rotation parallel to the normal of the major surfaces of said panel.
Preferably said device is a rotary device having an axis of rotation acute or perpendicular to the normal of the major surfaces said panel.
Preferably said guiding means is engagable against the tape applied edge of said panel to ensure the modifying means remains disposed at an appropriate distance in a plane parallel to the planes of the major surfaces of said panel from said panel.
Preferably said guiding means is engagable against the tape applied edge of said panel to ensure the modifying means remains disposed at an appropriate distance from said panel in a plane parallel to the planes of the major surfaces of said panel and wherein said guiding means includes an arcuate following surface with its centroid at the rotational axis of said rotary device, to ensure the guiding means maintains consistent positioning of the rotary device relative to the panel, over a broad range of rotational positions of said modifying unit relative to said fixed frame of reference.
Preferably said modifying unit includes a panel major surface tracer shoe engageable and biased towards a major surface of said panel to ensure the modifying means is maintained at a desirable spacing (in a direction normal to the surface of said panel) to said panel, so that any modifying of said tape by said modifying means is to a level not cutting into said panel.
Preferably said modifying means is a trimming means comprising two rotary cutters, each positioned to provide cutting of excess tape protruding beyond the level of each major surface of said panel.
Preferably each cutter is independently movable relative to said panel in a direction parallel to the normal of the major surfaces of said panel, each with its own designated tracer shoe to position a respective cutter at an appropriate level relative to a respective major surface.
Preferably said cutters are mounted relative to each other in a calliper like arrangement from a support structure of said modifying unit and biased towards each other in a direction parallel to the normal of the major surfaces of said panel.
Preferably said arm by which said modifying unit is pivotally mounted from said edge follower is an articulatable arm which includes a first arm portion pivotable about an axis (“first arm pivot axis”) at said edge follower and parallel to the normal of the major surfaces of said panel and a second arm pivotable relative to the first arm about an axis (“second arm pivot axis”) parallel to but displaced from the first arm pivot axis, said modifying means disposed from said second arm away from said second arm pivot axis.
Preferably said arm by which said modifying unit is pivotally mounted from said edge follower is an articulatable arm which includes a first arm portion pivotable about an axis (“first arm pivot axis”) at said edge follower and parallel to the normal of the said major surfaces of said panel and a second arm pivotable relative to the first arm about an axis (“second arm pivot axis”) parallel to but displaced from the first arm pivot axis, said modifying means disposed from said first arm away from said first arm pivot axis.
Preferably a biasing means, biases said second arm pivot axis, in use, towards the edge of said panel.
Preferably said the distal end of said second arm, in use, towards the edge of said panel.
Preferably said first arm includes an edge follower away from said first arm pivot (and preferably at said second arm pivot axis) to engage against said tape applied edge under the bias applied thereto.
Preferably said means to generate movement is provided by at least one driven roller of said edge follower having an axis of rotation substantially parallel to the normal of the major surfaces of said panel, wherein said driven roller is in use pressed against the edge of said panel, and upon its rotation generates relative movement between said edge follower and said panel.
Preferably said driven roller is the or at least one of said at least one edge contact roller.
Preferably one said at least one pressure roller is a said driven roller.
Preferably said at least one driven roller is provided in addition to said pressure roller.
Preferably said edge sensor is able to sense the angle of the edge at where said edge contact roller is pressed to said panel, relative to said frame of reference, by being responsive to the angle determined from the rotational position of said arm biased towards the edge of said panel, about its axis of pivot at said edge follower.
Preferably said means to mount said panel to said fixed structure mounts said panel in a non rotatable manner relative thereto.
Preferably said edge follower support structure is a gantry arrangement supported by and movable relative to said fixed structure, said gantry arrangement comprising
a bridging portion located to said fixed structure and translationally movable relative there to along a first path of travel
a traveller located to said bridging structure and translationally movable relative there to along a second path of travel being transverse to said first path, wherein said edge follower is mounted from said traveller to be displaced by said gantry arrangement in a Cartesian coordinate frame of reference, relative to said fixed structure.
Preferably said edge follower support structure is a swing arm arrangement supported by and movable relative to said fixed structure, said swing arm arrangement comprising
an arm pivotably located to said fixed structure about an axis of rotation
a traveler provided to said arm translationally movable along at least part of said arm wherein said edge follower is mounted from said traveler to be displaced by said swing arm arrangement in a polar coordinate frame of reference, relative to said fixed structure.
Accordingly in a second aspect the present invention consists in an edge banding apparatus to apply an edge tape to a contoured edge of a panel, said apparatus comprising;
a fixed structure to which a said panel can be mounted
an edge follower movably mounted from said fixed structure and adapted to move along at least part of said edge of said panel,
a sensing means to determine the direction of travel, relative to a chosen frame of reference, of said edge follower as it is moved along said edge profile
an active biasing means acting between said fixed structure and said edge follower responsive to feedback from said sensing means to act on said edge follower to control the direction of bias of said edge follower towards said panel
wherein said edge follower carries a driven rotatable means which engages with the edge of said panel to thereby generate the movement of said edge follower along at least part of said profile,
a means to advance edging tape between a pressure roller of said edge follower and the edge of said panel to be affixed to said panel at its edge, and
wherein a trailing tape modifying unit is dependent from the edge follower by an arm pivotable about an axis parallel to the normal of the major surfaces of said panel, said modifying unit biased towards the panel when in use in order to remain in contact with and to follow the edge of said panel, said modifying unit including at least one guiding means for guiding movement of said modifying unit relative to said panel.
Preferably said biasing means acts to bias said edge follower with a directional component normal to the direction of movement and normal to the normal of the major surfaces of said panel.
Preferably there is also a small component of direction of force of said biasing means on said edge follower in the direction of movement or opposite to the direction of movement of said edge follower along said edge profile.
Preferably a rotational force of said driven rotatable means provides a rolling action of said driven rotatable means to impart a displacement of said edge follower along said edge profile.
Preferably said driven rotatable means is also said pressure roller.
Preferably said sensing means senses the angle of said arm relative to said reference frame to thereby provide feedback to said biasing means of the angular orientation at or approximate to the point where the driven rotatable means is in contact with said edge profile, to thereby appropriately allow for control the direction of bias of said biasing means to said edge follower.
Accordingly in a further aspect the present invention consists in a method of edge banding an edge of a planar panel comprising
mounting a panel on a support structure
placing a pressure roller adjacent an edge of said panel and
whilst providing a feed of edge banding material to engage with said panel and which is fed onto said panel between the pressure roller and said panel, providing a rotation to an at least one rotating edge contact roller (whether it is also acting as the pressure roller or not) which is in contact with the edge of said panel advancing said pressure roller and/or said edge contact roller along said edge and which simultaneously deposits the edge tape to the edge of said panel,
controlling a vectored force application means applying a vectored force to the edge contact roller, which is controlled in response to the angle of the panel at said edge contact roller to thereby press said edge contact roller against the edge of said panel, and
wherein modifying of the edge applied tape occurs by a trailing tape modifying unit dependent from the pressure roller by an arm pivotable about an axis parallel to the normal of the major surfaces of said panel, said modifying unit biased towards the panel when in use in order to remain in contact with and to follow the edge of said panel, said modifying unit including at least one modifying means and at least one guiding means engaged to and for guiding movement of said modifying unit relative to said panel.
Accordingly in a further aspect the present invention consists in an edge tape modifying device for trailing an edge tape applicator which applies an edge tape to the edge of a contoured panel of a predetermined thickness by means of a pressure roller which is pressed against the edge of said panel and is displaced there along by means to move said pressure roller and wherein simultaneously an edge tape, is advanced to engage against the edge of said panel by being pressed there against by said pressure roller as said edge applicator advances about at least part of the perimeter of said panel, characterised in that said modifying device includes a swing arm pivotally dependent from edge tape applicator to be able to articulate relative thereto, said swing arm biased about said pivot for contact with the edge of the panel when in use, said modifying device including a modifying means supported by said swing arm away from said edge tape applicator, said modifying means biased towards yet guided for movement relative to the edge of said panel in order to perform a modifying operation on the edge applied edge tape.
Preferably said modifying means is also guided by a panel surface follower engagable and biased towards a major surface of said panel to ensure the modifying means is maintained at a desirable distance (in a direction normal to the surface of said panel) to the panel so that the modifying operation is at the appropriate distance relative to said surface of said panel.
Preferably said arm by which said modifying means is mounted is an articulatable arm which includes a first arm portion pivotable about an axis (“first arm pivot axis”) at said tape applicator follower and parallel to the normal of the major surfaces of said panel and a second arm pivotable relative to the first arm about an axis (“second arm pivot axis”) parallel to but displaced away from the first arm pivot axis, said modifying means disposed from said second arm away from said second arm pivot axis.
Preferably said arm by which said modifying means is mounted is an articulatable arm which includes a first arm portion pivotable about an axis (“first arm pivot axis”) at said tape applicator follower and parallel to the normal of the major surfaces of said panel and a second arm pivotable relative to the first arm about an axis (“second arm pivot axis”) parallel to but away displaced from the first arm pivot axis, said modifying means disposed from said second arm at said second arm pivot axis.
Preferably said arm by which said modifying means is mounted is an articulatable arm which includes a first arm portion pivotable about an axis (“first arm pivot axis”) at said tape applicator follower and parallel to the normal of the major surfaces of said panel and a second arm pivotable relative to the first arm about an axis (“second arm pivot axis”) parallel to but displaced away from the first arm pivot axis, said modifying means disposed from said first arm away from said first arm pivot axis.
Preferably said second arm is biased in use, from said first arm in a direction to be towards said panel by a torque force applied to said second arm from said first arm about said second arm pivot axis.
Preferably said first arm includes an edge follower at or proximate said second arm pivot axis to engage against said tape applied edge and biased there against.
Preferably said edge follower is a roller rotational about an axis coaxial with said second arm pivot axis.
Preferably said edge follower is a roller pivotable on a third pivot axis parallel to said second and first pivot axis and provided on said second arm away from said second pivot axis.
Preferably said modifying means is a trimming device to perform a trimming operation to any panel major surface protruding tape adjacent at least one and preferably both major surfaces of said panel.
Preferably said modifying means is a device being at least one selected from one or more of (a) a rotary cutter (b) a rotary sander (c) a rotary grinder.
Preferably said modifying means is a rotary device having an axis of rotation parallel to the normal of the major surfaces of said panel. Preferably said modifying means is a rotary device having an axis of rotation acute to the normal of the major surfaces said panel.
Preferably said modifying means includes a follower element for said guided movement engagable against the tape applied edge of said panel to ensure the modifying means remains disposed at an appropriate distance in a plane parallel to the major surfaces, from said panel.
Preferably said modifying means includes a follower element for said guided movement engagable against the tape applied edge of said panel to ensure it means remains disposed at an appropriate distance from said panel in a plane parallel to the major surfaces and wherein said follower element provides an arcuate following surface with its centroid at the rotational axis of said rotary device, to ensure the following means maintains consistent positioning of the rotary device relative to the panel, over a broad range of rotational positions of said modifying means relative to said applicator.
Preferably said modifying device includes a panel major surface tracer shoe engageable and biased towards a major surface of said panel to ensure the modifying means is maintained at a desirable distance (in a direction normal to the surface of said panel) to said panel so that any modifying of said tape by said modifying means is to a level not cutting into said panel.
Preferably said modifying means is a trimming means comprising two rotary cutters, each capable of being positioned to cut of excess tape protruding beyond the level of each major surface.
Preferably each cutter is independently movable relative to said panel each with its own designated tracer shoe to engage a respective major surface of said panel to position a respective cutter at an appropriate distance relative to a respective major surface to trim any protruding tape, yet not cut the panel itself.
Preferably said cutters are mounted relative to each other in a calliper like arrangement from a support structure of said modifying device and biased towards each other in a direction parallel to the normal of the major surfaces of said panel yet held in a separated relationship by said tracer shoes.
Preferably each cutter is independently movable relative to said panel in a direction parallel to the normal of the major surfaces of said panel, each with its own designated panel follower to position a respective cutting means at an appropriate level relative to a respective major surface.
Accordingly in a further aspect the present invention consists in an edge taping device which applies an edge tape to the edge of a contoured panel of a predetermined thickness by means of a pressure roller which is applied against the edge of said panel and is displaced there along by means to move said pressure roller and wherein an edge tape is advanced to engage against the edge of said panel and be pressed there against by said pressure roller as said edge applicator advances about at least part of the perimeter of said panel and
a triming attachment trailing the pressure roller supported by a swing arm able to articulate relative to the pressure roller, said pivot including a bias towards the panel when in use in order to remain in contact with said panel, said trimming attachment including at least one cutting means guided for movement relative to said panel in order to apply a trimming action to any panel major surface protruding tape adjacent at least one and preferably both major surfaces of said panel.
This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
A preferred form of the invention will now be described with reference to the accompanying drawings.
A trimming unit 12 of the present invention is movably dependent from a known form of tape unit 1. Whilst in one form the tape applicator unit may be of a kind which is exemplified by our PCT application WO02/14033 and which has in a simplified form been illustrated in
As shown in
In the most preferred form the trimming unit 12 is movably dependent from the support structure 80 by means of two articulated arms 20, 21. A first arm 20 is pivotally engaged to the support structure preferably about the C axis. A second arm 21 is pivotally dependent about axis H provided between the first arm 20 and second arm 21 at a location on the first arm 20 away from its pivot C relative to the support structure. A trailing roller 23 is carried by the first arm 20 and is provided to act and follow against the edge of the panel 3. The pivoting of the first arm 20 is about an axis (e.g. axis C) which is substantially normal to the surfaces of the panel 3. The pivot axis H is preferably parallel to the pivot axis C.
Dependent from the second arm 21 and away from its pivot axis H with the first arm 20 is a cutting means 26. The cutting means 26 preferably includes two cutters 30, 31 which include a plurality of cutting elements such as teeth which will be positioned relative to the panel so as to trim any excess top and bottom protruding tape extending beyond the first 81 and second 82 major surfaces of the panel 3. The cutters 30, 31 are dependent from the second arm 21 in a calliper like arrangement as for example shown in
In order to ensure that only the excess of the tape is trimmed, tracer shoes 40 are provided fixed relative to each cutter 30, 31. Each shoe 40 (shown in
The cutters 30, 31 are biased by a pneumatic cylinder (not shown) towards the panel 3 in order to ensure that each respective shoe 40 maintains contact with the major surface of the panel 3. Hence should the machine come to a variation in thickness of the panel the shoe will follow the increased thickness whether it is provided in the top or bottom side of the panel and move its respective cutter accordingly. In order to prevent the cutting means from engaging with the panel 3 a follower 50 is provided. The follower 50 will ensure that the cutters remain distally displaced at an appropriate distance from the edge of the panel (in a direction parallel to the major surfaces). The follower 50 is preferably fixed relative to the cutter axis S and is preferably dependent from the cutting means 26.
The arm 21 is pivotable and biased about the pivot axis H and in a direction to bias the follower 50 and hence the cutting elements towards the edge of the panel. Such bias is for example achieved by a servo motor. Drive means such as an electric motor 60 provides power to the cutters 30, 31. This preferably travels with the swing arm 21 and its rotation is preferably concentric with the rotation of the cutters 30, 31. Some form of coupling (such as a spline drive) may be provided between the lower cutter 30 and the motor 60 whereas the upper cutter 31 may be directly driven.
With reference to
Furthermore, the torque T which may need to be provided to encourage the cutter 26 to remain biased towards the edge of the panel 3 around the corner from the edge where the pressure roller is provided, may also need to be relatively high since the angle of the edge where the cutter is provided extends at a relatively shallow angle to the tangent of the arm rotatable about the pivot C of the pressure roller 4. Where both the pressure roller 4 and the cutter 26 are positioned against the same and a straight edge, the angle of the surface at where the cutter 26 is engaged is substantially normal to such a tangent, and such forces are not excessive.
Because of such inherent difficulties of maintaining adequate forces to advance the units around the panel the preferred form of the invention utilises shorter arm lengths so that sharp corners do not pose such angular problems. However, one important aspect that needs to be considered in the geometry of the present invention relates to the drying time required for the adhesive to take sufficient effect between the panel and the tape. Positioning of the cutter element too proximate to the pressure roller may not provide sufficient time for the adhesive to take effect to the extent required so that when the cutting of the excess tape occurs that the integrity of the bond between the panel and the tape is not adversely affected. An improvement to the single arm configuration shown in
It will be appreciated from the above, that the cutting device of the present invention can be used with a tape applicator which has a central pivot axis C about which in a relative manner the workpiece rotates, whilst keeping the application roller 4 pressing normal to the edge.
The mechanism described relies on a pivot arm 20 which rotates about the C axis but cannot move vertically (axially) in relation to the C Axis. At the end of this pivot arm 20 is a pressure roller 23 which is pressed against the panel 5 (trailing the C axis) by a torque system which may be a simple rotary pneumatic actuator driving a torque chain.
Connected and dependent from the pivot arm 20 is a second pivot arm 21 which is likely although not necessarily pivoted about the axis H of the trailing roller 23. Depending on the characteristics desired, the pivot point H may be different to this roller axis.
This second pivot arm 21 holds the trimming unit 26 which consists of a drive motor 60 driving through a spline drive to cutters 30, 31 which are able to float vertically and are aligned to the edge to be trimmed via horizontal and vertical tracer shoes 40. This unit is (like the first pivot arm 20 and trailing roller 23) is held against the panel 3 by a torque system.
A horizontal tracer shoe 50 is in part, of the same diameter as the datum diameter of the cutter 30, 31 so the shape remains the same even when the cutter is not held exactly normal to the panel when viewed about a vertical axis. This applies in particular when applying a radius to the edge tape requiring an accurate alignment of the cutters to the panel edge 5 in both the vertical and horizontal directions.
The mechanism described above being a knuckle type joint ensures the cutter unit 26 is kept at a reasonably normal aspect to the panel while also creating enough room to swing freely in the course of tracing the panel 3.
A further benefit of the knuckle joint is that by being relatively compact, a simple torque system maintains pressure against the panel without the need for complex compensation mechanisms during tracing tight corners.
As mentioned, if the first pivot is too long, there is a tendency for it to catch and be difficult to pull around tight corners.
The obvious benefit is in the significantly reduced cycle time and reduced complexity of the application machine. Thus the output relative to the capital investment is significantly improved over machines which require two processes.
The mechanism described particularly relates to automatic machines but could equally be mounted on manual machines so as to reduce cycle times. In these instances, the operator moves the aggregate (or panel - depending on the configuration) and the same benefits of single versus double process apply.
Whilst reference herein is made predominantly to the use of a trimming unit for trimming edge tape to ensure it is flush with the top and bottom surfaces of a panel, the cutter 26 and described with reference to such, can in an alternative configuration be substituted by other units capable of modifying the edge of the panel. For example a sanding unit or scraping unit or foil wrapping unit may be attached for the purposes of sanding or scraping or foil wrapping the edge subsequent to the application of tape thereto. As such the patent specification and the invention as defined in the claims is not limited to the process of trimming.
| Number | Date | Country | Kind |
|---|---|---|---|
| 526360 | May 2003 | NZ | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/NZ04/00112 | 5/31/2004 | WO | 9/6/2006 |
