CA2658278A1 - Vacuum suction transport carriage for a selection and bundling apparatus for random length materials - Google Patents
Vacuum suction transport carriage for a selection and bundling apparatus for random length materials Download PDFInfo
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- CA2658278A1 CA2658278A1 CA 2658278 CA2658278A CA2658278A1 CA 2658278 A1 CA2658278 A1 CA 2658278A1 CA 2658278 CA2658278 CA 2658278 CA 2658278 A CA2658278 A CA 2658278A CA 2658278 A1 CA2658278 A1 CA 2658278A1
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Abstract
A vacuum suction transport carriage includes a movably mounted carriage body, a vacuum suction generating device and a vacuum picker apparatus mounted on the carriage body, the vacuum picker apparatus including a main frame and at least two vacuum bar assemblies mounted on the main frame. These each include extension and retraction devices mounted on and extending downwards from the main frame and a vacuum bar mounted on a lower end of the extension and retraction device, the vacuum bar including a plurality of suction pads connected to the vacuum suction generating device. At least one of the at least two vacuum bar assemblies is transversely movably mounted on the main frame to alternatively increase and decrease the transverse distance therebetween to engage boards with the suction pads having suction applied thereto via the vacuum suction generating device for transport thereby, lift the boards via retraction of the extension and retraction device, and move the boards into adjacent proximity via transverse movement of the vacuum bar assemblies for transport of the boards.
Description
i . .. . . . . .
VACUUM SUCTION TRANSPORT CARRIAGE FOR A
SELECTION AND BUNDLING APPARATUS
FOR RANDOM LENGTH MATERIALS
[0001] The present application claims priority to U.S. Non-Provisional Patent Application Serial No. 11/717,834 filed on March 13, 2007, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
VACUUM SUCTION TRANSPORT CARRIAGE FOR A
SELECTION AND BUNDLING APPARATUS
FOR RANDOM LENGTH MATERIALS
[0001] The present application claims priority to U.S. Non-Provisional Patent Application Serial No. 11/717,834 filed on March 13, 2007, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] l.FIELD OF THE INVENTION
[0003] The present invention relates generally to a board row transfer device for an apparatus for selecting random length materials such as wood flooring stock and bundling nested combinations of the stock into a standard length, and more particularly to a vacuum suction transport carriage including two or more extendable vacuum bar assemblies mounted on a movable carriage body with at least one of the vacuum bar assemblies being transversely movably mounted on the body to permit the vacuum bar assemblies to be moved together or apart to access, lift and secure boards or rows of boards thereon for transport to a different location in the apparatus for continued automated sorting of a plurality of random length stock into standard length combinations for bundling.
[0004] 2. DESCRIPTION OF RELATED ART
[0005] Solid wood flooring is typically produced in random lengths, which vary from nine inches to eight feet long. The length is determined by cuts made to remove randomly placed defects in the natural raw material.
[0006] The flooring stock is typically shipped in standard bundles ranging from seven to eight feet long, and therefore the flooring stock is conventionally bundled in one or two ways: (1) sorting by length to the nearest even foot in length, with various length bundles included on a single pallet; and (2) nesting various lengths of wood stock into a standard bundle, typically seven to eight feet long. In either case, the top layer of flooring in each bundle is inverted, so that the face of the product is protected from damage during shipping and handling.
[0007] Nesting is becoming the preferred method of bundling, because it is easier to handle and ship and typically assures a random assortment of lengths for the installer. The most popular method for assembling random length wood flooring into nested bundles uses people to manually assemble the bundles. Generally, a person will first determine the grade of the flooring board by visual inspection. The inspected stock is then placed into a rack and sorted by its approximate length. A person on the other side of the rack will then remove selected pieces from one or more slots in the rack, visually judging the lengths to make a row of the desired standard length, when the pieces are nested end to end. In this method, the wood stock is generally sorted into approximate one foot increments. However, rarely are the boards exactly cut to the foot, and therefore are either longer or shorter than the increment slot in the rack in which it is placed. For this reason, once a combination of pieces is selected by the person assembling the bundle, it is often necessary to remove and replace various pieces to adjust the overall length of the nested row to fit the predetermined standard.
[0008] On the other hand, if the person grading the stock sorts the stock into racks with smaller increments, the sorting rack must necessarily be larger, and more time must be spent determining the proper slot in the rack for storage, as well as determining appropriate lengths for selection and nesting into the desired predetermined length row.
In some cases, a separate automated sorting mechanism is used to sort the wood stock by approximate length after grading. However, the nesting process is still currently accomplished manually by people. After enough rows of a proper length have been selected (usually twelve to fifteen rows for standard strip flooring) the top layer of product is manually inverted to protect the upper face of the product. The bundle is then tied together with plastic straps by a banding machine and the bundles are palletized for shipping.
In some cases, a separate automated sorting mechanism is used to sort the wood stock by approximate length after grading. However, the nesting process is still currently accomplished manually by people. After enough rows of a proper length have been selected (usually twelve to fifteen rows for standard strip flooring) the top layer of product is manually inverted to protect the upper face of the product. The bundle is then tied together with plastic straps by a banding machine and the bundles are palletized for shipping.
[0009] As each row of nested lengths are assembled into a stack forming a bundle, each row is typically abutted flush, allowing the distal ends of the rows to vary. Thus, the bundle will typically include a proximal end with all rows abutted flush, and a distal end with a "jagged" appearance because of the various completed lengths of rows. In an alternative bundling method, each end of the pieces of material are abutted against stops, forming flush ends, with the gaps between nested pieces located in the middle of the bundle.
Frequently, the interleaving of the pieces in this particular method is not adequate to hold the bundle together and the bundle is not as secure when bound. This method also makes it more difficult to estimate the total actual footage of the material in the bundle.
Because the longest and shortest rows in the bundle are typically four to six inches longer or shorter than the predetermined average, longer pallets are necessary for shipping and storage.
Frequently, the interleaving of the pieces in this particular method is not adequate to hold the bundle together and the bundle is not as secure when bound. This method also makes it more difficult to estimate the total actual footage of the material in the bundle.
Because the longest and shortest rows in the bundle are typically four to six inches longer or shorter than the predetermined average, longer pallets are necessary for shipping and storage.
[0010] In forming a "jagged end" bundle, the bundle assembler typically starts with a long piece of wood stock, or a combination of short pieces, and then chooses a short piece that will nest with the initial piece or pieces to approximate the desired predetermined length.
This results in most of the short pieces being located at the jagged end of the bundle, which can then be easily dislodged from the bundle during handling and shipping.
Frequently, when a truck or container of flooring is opened at its destination, dozens of short pieces of flooring have fallen from the bundles, with no way of determining which piece belongs to which bundle. This in turn results in a shortage of wood product from bundles, to the end user.
This results in most of the short pieces being located at the jagged end of the bundle, which can then be easily dislodged from the bundle during handling and shipping.
Frequently, when a truck or container of flooring is opened at its destination, dozens of short pieces of flooring have fallen from the bundles, with no way of determining which piece belongs to which bundle. This in turn results in a shortage of wood product from bundles, to the end user.
[0011] The process of assembling bundles is further complicated by the measuring rules commonly used in this industry. A standard machining or "end matching"
allowance of 3/4 inch is allowed on each piece of flooring. End matching is the process of putting a groove on one end of a piece of flooring stock and a tongue on the other end.
The tongue and groove then interlock to prevent displacement of the ends of the flooring over time. The standard method of measurement for wood flooring calls for the addition of 3/4 inch to the length of the face of each piece, in order to allow for the material which is necessarily removed by the end matching process. This means that, if a row is being assembled for a standard length bundle, it may be 3/4 inch short if the row consists of one piece of wood stock, 1%z inches short if made up of two pieces of wood stock, etc. In practice, the average length is assumed, and the target bundle length is shortened by the required amount.
allowance of 3/4 inch is allowed on each piece of flooring. End matching is the process of putting a groove on one end of a piece of flooring stock and a tongue on the other end.
The tongue and groove then interlock to prevent displacement of the ends of the flooring over time. The standard method of measurement for wood flooring calls for the addition of 3/4 inch to the length of the face of each piece, in order to allow for the material which is necessarily removed by the end matching process. This means that, if a row is being assembled for a standard length bundle, it may be 3/4 inch short if the row consists of one piece of wood stock, 1%z inches short if made up of two pieces of wood stock, etc. In practice, the average length is assumed, and the target bundle length is shortened by the required amount.
[0012] Industry grading rules also require a minimum average length for each grade.
The system of the present invention allows the processor to easily keep track of this information. The current process of creating nested rows to form bundles by hand is time consuming, tedious, and proficiency requires consider experience. Some bundle assemblers never become good at choosing an acceptable combination of wood stock lengths on the first or second try, and therefore must spend additional time in a trial and error process to form a bundle. Further, the manual process of selecting rows for a bundle is not particularly accurate when assembled by hand, especially if the person assembling the bundle is in a hurry to create the bundle. Further, once assembled, it is difficult to obtain an accurate measure of the material which is included in each bundle, especially if the method of forming the bundle with two flush ends is utilized.
The system of the present invention allows the processor to easily keep track of this information. The current process of creating nested rows to form bundles by hand is time consuming, tedious, and proficiency requires consider experience. Some bundle assemblers never become good at choosing an acceptable combination of wood stock lengths on the first or second try, and therefore must spend additional time in a trial and error process to form a bundle. Further, the manual process of selecting rows for a bundle is not particularly accurate when assembled by hand, especially if the person assembling the bundle is in a hurry to create the bundle. Further, once assembled, it is difficult to obtain an accurate measure of the material which is included in each bundle, especially if the method of forming the bundle with two flush ends is utilized.
[0013] Several methods and devices have been proposed in the prior art, including Ahrens, U.S. Patent Nos. 6,510,364 and 6,598,747. While the previous Ahrens patents do address many of these issues, the method used has some limitations. The measurement method is not particularly accurate, and may change as the feed wheels wear and is affected by feed wheel slippage. Also, the speed at which the Ahrens machine operates is not adequate to handle the production of a large flooring mill. It is designed to handle only one grade, and is not easily adapted to multiple grades. No provision is made for automation in loading the machine. Graders must still handle the boards in order to grade and load the machine. Finally and perhaps most importantly, however, the prior art method of Ahrens utilizes an entirely different sort method, specifically that it accumulated up to 16 individual boards in a storage rack and then determined the preferable solution consisting of one or more boards to form a row within the minimum and maximum tolerances. The number of possible combinations available in this scenario, however, is in the thousands, and even after computing all of these combinations, the end result is only a single completed row, which greatly increases the inefficiency of the sorting process.
[0014] It is therefore a general object of the present invention to provide an improved bundling apparatus for selecting random length pieces of product to form standard length bundles. This improved apparatus will include provisions for automatic loading if desired, essentially unlimited number of grades, and is able to handle 180 pieces or more of flooring per minute, adequate for most high speed flooring mills. Measuring accuracy is improved greatly, and grading can be accomplished without touching the material.
[0015] Another object is to provide a bundling apparatus which is automated to improve the accuracy of the overall length of rows within a bundle and the average bundle size.
[0016] A further object of the present invention is to provide an automated bundling apparatus which is capable of documenting the length of pieces within a bundle more accurately than possible when assembled by hand or by use of the disclosed prior art.
[0017] Still another object is to provide a bundling apparatus which is capable of tracking minimum average length information for each grade of product. Also, the improved apparatus gives the operator the option of maintaining an average length for a given grade of product by any of several methods. If the average length of the current production run is less than the desired target, the machine may reject short boards, downgrade short boards to a grade with lower average length requirements, or bundle short boards as a separate grade, allowing them to be sold as such, or blended back into production when the average length is more than required. The last is the preferred solution, since it allows full price to be realized for the short pieces and also improves consistency of product.
[0018] Finally, an object of the present invention is to provide an improved sorting and bundling apparatus which is relatively durable in construction and is safe, efficient and effective in use.
[0019] These and other objects of the present invention will be apparent to those skilled in the art.
BRIEF SUMMARY OF THE INVENTION
BRIEF SUMMARY OF THE INVENTION
[0020] The present invention provides an apparatus for selecting and sorting a plurality of random length boards to form at least one row of boards having a total length within a predetermined target length range which includes a measurement section operative to support and measure the length of each of the plurality of random length boards and a sorting section which includes a sorting device and system operative to sort each of the plurality of boards.
An accumulating row section includes a plurality of accumulating rows in board transfer connection with the sorting section each for accumulating and storing a row of boards selected from the plurality of boards and a board row transfer device such as a vacuum suction transport device is operative to move a row of boards from at least one of the plurality of accumulating rows to a bundling section. The bundling section receives and retains rows of boards from the board row transfer device, the bundling section further including a bundling device operative to generally bunch and align the rows of boards and bundle the rows of boards in a board row bundle. Finally, a central processor is included which is operative to receive the length information from the measurement section, associate the length information with each of the plurality of random length boards, determine into which of the plurality of accumulating rows each of the plurality of random length boards is to be sorted, engage the sorting device and system to direct each of the plurality of random length boards into the accumulating row section to fill at least some of the plurality of accumulating rows with selected boards from the plurality of random length boards such that the selected boards in at least some of the plurality of accumulating rows have a total length within a predetermined target length range, the central processor further operative to engage the board row transfer device to move a row of boards from a selected one of the plurality of accumulating rows to the bundling section upon detecting the selected one of the plurality of accumulating rows having a row of boards stored therein which has a total length within the predetermined target length range thereby forming bundles of rows of boards having a total length generally within the predetermined target length range.
An accumulating row section includes a plurality of accumulating rows in board transfer connection with the sorting section each for accumulating and storing a row of boards selected from the plurality of boards and a board row transfer device such as a vacuum suction transport device is operative to move a row of boards from at least one of the plurality of accumulating rows to a bundling section. The bundling section receives and retains rows of boards from the board row transfer device, the bundling section further including a bundling device operative to generally bunch and align the rows of boards and bundle the rows of boards in a board row bundle. Finally, a central processor is included which is operative to receive the length information from the measurement section, associate the length information with each of the plurality of random length boards, determine into which of the plurality of accumulating rows each of the plurality of random length boards is to be sorted, engage the sorting device and system to direct each of the plurality of random length boards into the accumulating row section to fill at least some of the plurality of accumulating rows with selected boards from the plurality of random length boards such that the selected boards in at least some of the plurality of accumulating rows have a total length within a predetermined target length range, the central processor further operative to engage the board row transfer device to move a row of boards from a selected one of the plurality of accumulating rows to the bundling section upon detecting the selected one of the plurality of accumulating rows having a row of boards stored therein which has a total length within the predetermined target length range thereby forming bundles of rows of boards having a total length generally within the predetermined target length range.
[0021] The present invention also contemplates a vacuum suction transport carriage operative to interact with an apparatus for selecting and sorting a plurality of random length boards to form at least one row of boards having a total length within a predetermined target length range, the vacuum suction transport carriage including a carriage body including rollers mounted thereon, a vacuum suction generating device and a vacuum picker apparatus mounted on the carriage body, the vacuum picker apparatus including a main frame and at least two vacuum bar assemblies mounted on the main frame. Each of the at least two vacuum bar assemblies include extension and retraction devices mounted on and extending downwards from the main frame and a vacuum bar mounted on a lower end of the extension and retraction device, the vacuum bar including a plurality of suction pads connected to the vacuum suction generating device. At least one of the at least two vacuum bar assemblies is transversely movably mounted on the main frame whereby transverse movement of the at least one of the at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between the at least two vacuum bar assemblies; and the at least two vacuum bar assemblies are operative to each be extended downwards from the main frame via extension of the extension and retraction device to engage boards with the suction pads having suction applied thereto via the vacuum suction generating device for transport thereby, lift the boards via retraction of the extension and retraction device, and move the boards into adjacent proximity via transverse movement of the at least one of the at least two vacuum bar assemblies for transport of the boards.
[0022] The present invention as thus described provides substantial advantages over those board sorting and bundling devices and systems found in the prior art.
For example, because the present invention sorts the boards as they are processed through the apparatus in a generally continuous fashion, the efficiency of the process and the efficiency of operation of the apparatus is increased significantly over previous devices and methods.
Furthermore, because the present invention and method automates the sorting and bundling process, users of the present invention will see large savings in labor and expense over those prior art devices and methods, which will significantly improve the user's bottom line.
Finally, because the process and method of the present invention generally eliminates the need for manual manipulation of the boards in the sorting and bundling process, users of the present invention will see significant increases in safety and likely will see significant decreases in the amount of time lost to injury and disability caused by accidents occurring during the sorting and bundling process. It is therefore seen that the present invention provides a substantial improvement over those methods, systems and devices found in the prior art..
BRIEF DESCRIPTION OF THE DRAWINGS
For example, because the present invention sorts the boards as they are processed through the apparatus in a generally continuous fashion, the efficiency of the process and the efficiency of operation of the apparatus is increased significantly over previous devices and methods.
Furthermore, because the present invention and method automates the sorting and bundling process, users of the present invention will see large savings in labor and expense over those prior art devices and methods, which will significantly improve the user's bottom line.
Finally, because the process and method of the present invention generally eliminates the need for manual manipulation of the boards in the sorting and bundling process, users of the present invention will see significant increases in safety and likely will see significant decreases in the amount of time lost to injury and disability caused by accidents occurring during the sorting and bundling process. It is therefore seen that the present invention provides a substantial improvement over those methods, systems and devices found in the prior art..
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Figure 1 is a perspective view of the board sorting and bundling apparatus of the present invention;
[0024] Figure 2 is a top plan view of the present invention showing the board flow through the device;
[0025] Figure 3 is a perspective view of the sorting section and the accumulating row section of the present invention;
[0026] Figure 4 is a detailed side elevational view of the board drop channels of the present invention;
[0027] Figure 5 is a detailed perspective view of the measuring section of the present invention showing the light curtain measuring the boards passing through the invention;
[0028] Figure 6 is a detailed view of the computerized central processor 180 of the present invention showing the fill levels of various accumulator rows;
[0029] Figure 7 is a detailed side elevational view of the initial end of the sorting section;
[0030] Figure 8 is a detailed perspective view of the gates of the sorting section with a board being pushed therealong by an overhead lug;
[0031] Figures 9a and 9b are detailed side elevational views of the process by which a gate is opened to receive a board;
[0032] Figure 10 is a detailed perspective view of the accumulating row section and the vacuum suction transport carriage in operation;
[0033] Figures 11 and 12 are, respectively, a detailed perspective view and a detailed side elevational view of the flipping device of the present invention;
[0034] Figure 13 is an end elevational view of the bundling section of the present invention bundling a bundle;
[0035] Figure 14 is a detailed perspective view of the bundling section of the present invention;
[0036] Figure 15 is a detailed side elevational view of the bundling section;
[0037] Figure 16 is a detailed perspective view of a completed bundle;
[0038] Figures 17-22 are flowcharts which show the method of sorting boards of the present invention.;
[0039] Figure 23 is a perspective view of the preferred embodiment of the vacuum suction transport carriage of the present invention;
[0040] Figure 24 is a detailed perspective view of the vacuum picker section of the vacuum suction transport carriage;
[0041] Figure 25 is a detailed top plan view of the vacuum picker section; and [0042] Figure 26 is a detailed bottom perspective view of the vacuum picker section showing the vacuum bars and vacuum pads thereon.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0043] The selection and bundling apparatus 10 of the present invention is shown best in Figures 1-16 as including an infeed section 20, a measurement section 40, a sorting section 60, a row accumulating section 80, a bundling section 100 including one or more bundling devices 102 which further is operatively associated with a layer inverting device 120, and a vacuum suction transport carriage 140 operative to transport the accumulated rows of boards from the accumulator rows to the bundling section 100.
[0044] Referring now to Figures 1 and 2, infeed section 20 includes a support frame 22 supporting at least one inflow conveyor belt 24 having a forward end 26 and a rearward end 28. Mounted atop the conveyor belt are guide rails 30a and 30b which extend in convergent configuration to one another to guide the incoming board 200 down the inflow conveyor belt 24 towards rearward end 28 thereof. Preferably, the inflow conveyor belt 24 is operated at a speed which carries the boards 200 at a rate of approximately sixty (60) feet per minute, although it should be noted that this speed and in fact the other speeds of belts and drive wheels to be disclosed here may be changed or modified to adjust the operational characteristics of the present invention, and such modifications and changes should be understood to be a part of this disclosure. Also, each board 200 is preferably of uniform width and thickness, but has a variety of unequal, random lengths based upon cuts made to remove defects from the natural raw material, and it is these unequal lengths which has necessitated the development of the present invention.
[0045] The boards 200 are received as a plurality of random length boards which have been cut and processed earlier and are being delivered by conveyor belt 16 to the infeed section 20, and at this time or earlier in the cutting and finishing process, the grade of each board 200 must be determined. This may be accomplished by an automated grading scanner, a human grader inputting the grade with a switch or joystick or by a human placing each separate grade in a predetermined place such that the machine can determine its source, specifically by using different and multiple inflow conveyor belts each of which are associated with different grades of boards. Of course, the grading may also be entered directly into the central processor 180 which will keep an array of boards in its memory such that each board 200 passing through the present invention is uniquely tracked to ensure that differently graded boards are not included with the wrong grade. The boards 200 are then fed by a loading device or by hand into the board sorting and bundling device of the present invention, although the manual entry of the boards 200 is not currently recommended whereas the entry of the boards 200 by a preferred loading device is described herein.
[0046] Mounted at the rearward end 28 of inflow conveyor belt 24 at the rear end of the convergent guide rails 30a and 30b are board drop channels 36, as shown best in Figure 4, which are connected to the central processor 180 to identify when a board 200 is in the board drop channel 36 and which then waits until an appropriate drop time occurs when the board 200 may be dropped into the receiving portion of the measurement section 40. When that drop time occurs, the central processor 180 signals the board drop channel 36 to open to drop the board 200 into the receiving portion of the measurement section 40, and in the preferred embodiment, the board drop channel 36 would include drop doors 38a and 38b which would open to drop the board 200 upon receiving the drop signal from the central processor 180.
[0047] As shown in Figures 1, 2, 4 and 5, the next section into which the board 200 will pass is the measurement section 40 which, in the preferred embodiment includes a plurality of lugs 44 extending across the floor 42 of the device 10, a lug 44 being an upright transversely extended plate or bar, with each of the lugs being supported by a driven roller chain or another such generally constant speed drive mechanism on each end (i.e. opposite sides of the measurement section 40) such that the lugs 44 remain parallel and evenly spaced.
Each lug 44 supports and pushes a single board 200, and the grade of each board 200 is noted by the computerized central processor 180 so that the processor knows what is the grade of each board. The boards are dropped into the measurement section 40 such that the boards 200 fall between the lugs 44, and the central processor 200 specifies the drop of each board 200 based on the sensed position of each of the lugs 44, thereby ensuring that only one board will be placed in front of each lug 44.
Each lug 44 supports and pushes a single board 200, and the grade of each board 200 is noted by the computerized central processor 180 so that the processor knows what is the grade of each board. The boards are dropped into the measurement section 40 such that the boards 200 fall between the lugs 44, and the central processor 200 specifies the drop of each board 200 based on the sensed position of each of the lugs 44, thereby ensuring that only one board will be placed in front of each lug 44.
[0048] A series of longitudinally extended positioning rollers 46 are rotatably mounted adjacent and forward of the first section of floor 42 underneath the lugs 44. As the lugs 44 move the boards 200 held thereby forwards over the floor 42 of measurement section 40, the boards 200 contact the spinning positioning rollers 46 which drive each board 200 over to the inner side of the measurement section 40 against the inner guide wall 48 of the measurement section 40, as shown in Figure 2, thus aligning the inner sides of each of the boards 200 against the inner guide wall 48 and thereby simplifying the board measuring process about to be described herein. Of course, it is not strictly necessary to include such positioning rollers 46, but it has been found that the alignment of the boards 200 against the inner guide wall 48 facilitates continued processing of the boards 200 traveling through the invention.
[0049] As shown best in Figure 5, the main element of the measurement section 40 is the light curtain 50 which determines the length of each board and preferably includes a series of LED senders and receivers, as is well known in the trade, which determines the length of the board as it is conveyed by the lugs 44 along the floor 42 of the measurement section 40 from the loading device area to the sorting section 60, and this information is likewise transmitted and retained by the computerized central processor 180.
The light curtain 50 may be constructed of a single transversely extended light bar or two or more light bars aligned collinearly with one another to provide a measurement device which extends across the entire floor 42 and can measure even the longest boards being sorted by the present invention. As was discussed previously, the board length measurement of the board 200 is transferred to the computerized central processor 180 which it enters the board array stored in the computerized central processor 180 along with the grading information for each board 200.
The light curtain 50 may be constructed of a single transversely extended light bar or two or more light bars aligned collinearly with one another to provide a measurement device which extends across the entire floor 42 and can measure even the longest boards being sorted by the present invention. As was discussed previously, the board length measurement of the board 200 is transferred to the computerized central processor 180 which it enters the board array stored in the computerized central processor 180 along with the grading information for each board 200.
[0050] The board 200 is then transferred from the measurement section 40 to the sorting section 60 via a rotating transfer wheel 52. In the preferred embodiment, the rotating transfer wheel 52 rotates with an angular velocity which is generally identical to the speed of travel of the lugs 44, and would include a plurality of transversely extending board transfer bars 54 having generally L-shaped cross-sectional shapes which engage each of the boards 200 as they exit the measurement section and lift them out of the lugs 44 in which they were traveling, then carry them over to the sorting section 60 where each board 200 is dropped onto the floor 62 of the sorting section 60 for engagement by the pushing devices which move the boards 200 through the sorting section, as shown best in Figure 7.
However, it is not always necessary to provide the lifting and accelerating of the boards if there is a direct transfer from the end matcher or the measurement section, in which case the spacing and speed of the prior existing machine would need to be matched. In this case, one solution would be to provide a split chain section to accelerate and widen the spacing of the boards to allow sorting. However, one continuous chain on approximately 12" centers may be used when standard loading procedures and devices are used, but the sorting section 60 of the present invention would still preferably be positioned below the measuring section 40 of the device.
However, it is not always necessary to provide the lifting and accelerating of the boards if there is a direct transfer from the end matcher or the measurement section, in which case the spacing and speed of the prior existing machine would need to be matched. In this case, one solution would be to provide a split chain section to accelerate and widen the spacing of the boards to allow sorting. However, one continuous chain on approximately 12" centers may be used when standard loading procedures and devices are used, but the sorting section 60 of the present invention would still preferably be positioned below the measuring section 40 of the device.
[0051] In the preferred embodiment, each of the boards 200 would be engaged by an overhead lug 64 which is generally similar in design and construction to lugs 44 but is elevated above the floor 62, as shown best in Figures 7-9. Each of the overhead lugs 64 preferably includes a plurality of forwardly and downwardly depending "D"-springs 66 and associated downwardly depending push spring bars 72 each positioned rearwards of an adjacent "D"-spring 66 such that the lower curve 68 of the "D"-springs 66 engages the top surface 202 of the board 200 as the overhead lug 64 passes over and engages a board 200 dropped in front of the overhead lug 64 by the rotating transfer wheel, and the "D"-springs 66 press the board 200 downwards to keep the board 200 from bouncing or shifting as it is moved along the sorting section 60, and the rear edge 204 of the board 200 is engaged by the lower portion 74 of each of the push spring bars 72 to push the board 200 forwards along the sorting section 60 yet allow the board 200 to pop out of the lug 64 if the board 200 becomes jammed on the sorting section 60, thereby preventing the device 10 from being damaged should a jam take place. It has been found that the configuration of the overhead lugs 64, the "D"-springs 66 and associated downwardly depending push spring bars 72 is important to the operation of the present invention in order to properly and efficiently move the boards 200 through the sorting section 60, and although variations in the mechanisms used to move the boards 200 through the sorting section 60 should be understood to be a part of this disclosure, such as the use of a polyurethane flap which replaces the "D"-springs 66, it is preferred that the overhead lugs 64 be used as described herein for optimal performance.
[0052] A series of transversely extending gates 76 are positioned in parallel configuration and pivotably mounted along the floor 62 of the sorting section 60 over which the board 200 is traveling, as shown in Figures 8 and 9, and as each board 200 enters the sorting section 60, the central processor 180 identifies the appropriate row into which the board 200 should be deposited by applying a sorting algorithm successively to each board 200 which will be described in more detail later in this disclosure. In the preferred embodiment, there are a plurality of gates 76 associated with each grade of board in a dynamic allocation design, and the processor 180 then activates the selected gate 76 on the sorting section 60, as shown in Figure 9, so that the gate plate 77 pops up via activation of its associated pneumatic or hydraulic cylinder 78, the board 200 hits the gate plate 77 and begins to fall down below the gate 76, and the gate plate 77 then shuts by reverse activation of the pneumatic cylinder 78 thus forcing the board 200 downwards onto a set of transfer belts or rollers 79 which are in constant rotational motion to drive the board 200 transversely between the gates 76 along the selected gate line over to the accumulating row section 80. Because the pivoting mount of each of the gates extends below the level of the gate plate 77, the space directly beneath the gate plate 77 accommodates the board 200 which rests on the transfer rollers 79 so that the board 200 travels between the gate pivots underneath the selected gate 76 over to the accumulator row section 80 described hereinafter.
[0053] The accumulator row section 80 in the preferred embodiment is shown best in Figures 3 and 10 as including a plurality of transversely extending accumulating rows 84 separated by upright bars 86 and 88 which extend parallel with one another and are adjustably mounted on the accumulating row section frame 82 such that the width of the accumulating rows 84 may be adjusted by a row width adjustment mechanism 90 by the user of the present invention to accommodate boards 200 of different widths. The transfer rollers 79 engage the boards 200 and push them into the selected accumulating row 84, and it should be noted that to ensure proper transfer of the boards 200 from the gates 76 to the accumulating rows 84, it may be necessary to provide adjustable transfer guide walls 92 which extend between the ends of the gates 76 and the feed openings of the accumulating rows 84, although the precise nature of those transfer guide walls 92 is not particularly critical to the operation of the present invention so long as the guide function of transferring the boards 200 from the sorting section 60 to the accumulating row section 80.
[0054] As the board enters the selected row 84 of the accumulating row section 80, the central processor 180 tracks the status of each accumulating row. Once the set of boards 200 within a particular row 84 reaches a total length which falls within the predetermined target length range, the central processor 180 dispatches a vacuum suction transport carriage 140 which is supported on rails 142a and 142b or tracks above the accumulating row section 80 and travels perpendicular to the positioning of the row of boards within the accumulating rows 84 so that the accumulating row 84 where the entire row of boards is to be picked up is easily accessed, picked up and supported by the carriage 140, as shown in Figure 10. In the preferred embodiment, the vacuum suction transport carriage 140 includes a carriage frame 142 which includes a set of rail-engaging wheels 152a and 152b mounted on opposite ends of the carriage 140. The vacuum suction device includes at least two rows of suction cups or pads connected to a vacuum source for generating a significant degree of suction at each of the two rows of suction cups or pads. The two rows of suction cups or pads are adjustably mounted on the carriage frame 142 such that the spacing between the rows of suction cups or pads may be adjusted to initially pick up two rows of boards 200 and then the rows of suction cups or pads may be moved towards one another to bring the two rows of boards 200 into adjacent contact with one another prior to being moved to the bundling section 100. In the preferred embodiment, however, it should be noted that the carriage 140 will have three rows of suction cups so that three rows of boards 200 may be picked up and transferred to the bundling section 100 at the same time. Also, the present invention contemplates simultaneous use of two or more carriages 140 which travel over the accumulating row section 80 and transfer the collected rows of boards 200 to one of several bundling sections 100 including one or more bundling devices 102 which will be described later in this disclosure.
[00551 The vacuum section transport carriage 140 of the present invention is shown best in Figures 23-26 as including a carriage body 141 which includes a main frame 142, including lower carriage frame beams 416a and 416b and upper carriage frame beams 418a and 418b which are connected to and extend between outer frame support plates 420a and 420b. In the preferred embodiment, the carriage body 141 would have dimensions of approximately eight to ten feet in length, two to four feet in width, and two to three feet in height, although the exact dimensions of the carriage body 141 will generally be determined by dimensions of the accumulator row section 80 and accumulator rows 84 over which the vacuum suction transport carriage 140 is traveling, as shown best in Figure 10. Mounted on and extending between the lower carriage frame beams 416a and 416b is the vacuum picker assembly 460 which will be described later in this disclosure.
[0056] Rotatably mounted on the lower portions of the outer frame support plates 420a and 420b are a plurality of carriage roller wheels 422a, 422b, 422c and 422d, which fit within the support rails of the selection bundling apparatus on which the vacuum section transport carriage 140 is mounted, although it should be noted that many different types of carriage roller wheels, slides or other movement-facilitating devices may be used with the present invention so long as the vacuum section transport carriage 140 is able to freely move back and forth on the selection bundling apparatus to pick up and transport rows of boards.
The drive mechanism 424 for the vacuum section transport carriage 140 may be of many different kinds, including providing the vacuum section transport carriage 140 with a self-propulsion unit such as an electric motor which drives the carriage roller wheels 422a-d or generally any other type of propulsion device which is controllable by the central controller computer of the selection bundling apparatus 10, but in the preferred embodiment, it is preferred that the drive mechanism 424 be a chain drive, rack and pinion gear system, timing belts, or another such drive device, depending on the performance preferences desired by the manufacturer and/or user of the present invention. The mechanism further includes a plurality of drive gears 426a and 426b through which the chain drive (as shown in Figure 10) extends. The chain drive would then pass over the main drive gear 428 through which drive shaft 430 extends, and as drive shaft 430 is rotated in response to commands issuing from the central computer system of the selection and bundling apparatus 10 to move the vacuum section transport carriage 140 to the selected accumulator row 84 at which the row of boards is to be picked up for movement to the bundling area 100 of the selection and bundling apparatus 10. In the preferred embodiment, drive shaft 430 would be driven via connection to an electric motor 432 having a bank of capacitors 434 connected thereto for modulating and controlling the electrical current flowing to the electric motor 432 in order to ensure that exceptionally accurate engagement and control of the electric motor 432 is achieved. Of course, there are many different electrical system arrangements which may be used in connection with the present invention which would fulfill the same general functions of the electric motor 432 of the present invention, and such variations and substitutions should be understood to be a part of this disclosure. It should be further noted that in the preferred embodiment the electric motor 432 would be mounted on a mounting frame 436 adjacent the end of drive shaft 430, although the precise mounting design used in connection with the electric motor 432, capacitors 434, and remaining functional elements of the drive system are not particularly critical to the present invention so long as the functional features and performance characteristics are generally maintained.
[0057] An important design feature of the present invention is that the carriage body 141 and in fact the various elements of the main frame 142 are not particularly critical to the functionality of the present invention so long as the carriage body 141 may freely move back and forth above the accumulator rows 84 on the selection and bundling apparatus to access rows of boards which the central computing system has determined need to be picked up and moved to the bundling sections. The truly critical features of the vacuum section transport carriage 140 of the present invention are shown best in Figures 24-26, however; as including the vacuum picker assembly 460 which, in the preferred embodiment, would include a main frame 462 having frame end bars 464a and 464b, each of which are generally L-shaped in cross-sectional shape and inner frame bars 466a and 466b which provide additional structural strength to the main frame 462 of vacuum picker assembly 460, as shown best in Figures 24, 25, and 26. The main operative elements of vacuum picker assembly 460, however, are the three vacuum bar assemblies 470, 480, and 490 which, in the preferred embodiment, are generally identical to one another in function, and therefore the following description of center vacuum bar assembly 480 should be understood to apply equally to vacuum bar assemblies 470 and 490. Center vacuum bar assembly 480 would preferably include a main support beam 482 which is mounted on and extends between the inner frame bars 466a and 466b, as shown best in Figures 24-26. Mounted on the main support beam 482 are a pair of lineal shafts 484a and 484b which keep the suction bars parallel, and there is preferably only one pneumatic cylinder 1000a, 1000b and 1000c, on each of the vacuum bar assemblies 470, 480 and 490, the lower ends of which are connected to a vacuum bar support frame 486.
Mounted on and extending parallel with the vacuum bar support frame 486 is the center vacuum bar 488 itself which, in the preferred embodiment, will be a longitudinally extended bar having a plurality of suction pads 489 mounted on the underside thereof, as shown best in Figure 26. It should be noted that the suction pads 489 may be of many different sizes and shapes, and, in fact, may be formed as a plurality of suction cups should such a configuration be deemed superior for the purposes for which the vacuum section transport carriage 140 is to be used. However, it has been found that a plurality of suction pads 489 having connections to a central vacuum generating device 440 is the preferred structural design for the present invention.
[0058] As was discussed previously, the right vacuum bar assembly 470 and left vacuum bar assembly 490 are generally identical to the center vacuum bar assembly 480 in structural design, however, the significant difference between the right and left vacuum bar assemblies 470 and 490 and center vacuum bar assembly 480 is that the right and left vacuum bar assemblies 470 and 490 are movably mounted on the main frame 462 of vacuum picker assembly 460 so that they may move towards or away from the center vacuum bar assembly 480 in a direction generally perpendicular (specifically, tranversely on the vacuum picker assembly 460) to the center vacuum bar 480, as shown best in Figures 24-26. It should be noted that the precise mechanism by which the right and left vacuum bar assemblies 470 and 490 are moved relative to the center vacuum bar assembly 480 is not critical to the present invention so long as the positioning and movement of the right and left vacuum bar assemblies 470 and 490 relative to the center vacuum bar assembly 480 may be precisely adjusted and quickly and easily configured. In the preferred embodiment shown in Figures 24-26, however, the vacuum bar assembly movement mechanism 500 would include two slide mount bars 502a and 502b on which are slidably mounted the main support beams 472 and 492 of right and left vacuum bar assemblies 470 and 490, as shown best in Figure 25. In the preferred embodiment, the slide mount bars 502a and 502b would be generally cylindrical in cross-sectional shape and would extend generally parallel with the outer and inner frame bars 464a, 464b, 466a, and 466b. The right and left main support beams 472, 482 and 492 would be slidably mounted on the slide mount bars 502a and 502b by bar engagement brackets, with the right and left bar mounting standards 504a, 504b, 506a and 506b being slidably mounted on a respective one of the slide mount bars 502a and 502b on a plurality of lineal bearings 505a, 505b, 507a and 507b so that the right main support beam 472 and left main support beam 492 extend generally parallel with the main support beam 482 of center vacuum bar assembly 480, as shown best in Figure 25.
[0059] To adjust the horizontal positions of the left and right vacuum bar assemblies 470 and 490 relative to center vacuum bar assembly 480, a rotating chain drive positioning assembly 510 is rotatably mounted adjacent outer frame bar 464a with right bar engagement bracket 504a 525b being connected thereto via connection bracket 514 which is connected to chain 512. Likewise, left chain drive positioning assembly 520 is positioned adjacent outer frame bar 464b and the drive chain 522 of left chain drive positioning assembly 520 is operatively connected to left bar engagement bracket 506a of left main support beam 492 via left connection bracket 524, as shown best in Figures 25 and 26. A pair of rotating drive shafts 530 and 532 extend between and connect the opposite ends of the right and left chain drive positioning assemblies 510 and 520, with the connection of first drive shaft 530 to right chain drive positioning assembly 510 being a fixed connection to drive chain 512 and the connection of first drive shaft 530 to left chain drive positioning assembly 520 also being a fixed connection so that the shafts 530 and 532 always rotate in the same direction at the same speed. The right vacuum bar assembly 490 is attached to the top strand of both chains, and the left vacuum bar assembly 470 is attached to the bottom strand of both chains. This arrangement forces the bars to move in opposite directions from the center bar, but still keeps both outside bars equidistant from and parallel to the center bar. This is best shown in Figure 24. In this manner, the horizontal positions of right vacuum bar assembly 470 and left vacuum bar assembly 490 relative to center vacuum bar assembly 480 may be precisely determined and adjusted by engagement of first and second drive shafts 530 and 532 which respectively drive right chain drive positioning assembly 510 and left chain drive positioning assembly 520 to move the right and left main support beams 472 and 492 on slide mount bars 502a and 502b.
[0060] Left and right positioning pneumatic cylinder assemblies 540 and 542 would each include a mounting bracket and a stack of four (4) pnuematic cylinders operatively connected to the right vacuum bar assembly 470 and left vacuum bar assembly 490. The four cylinders are preferably each a different stroke, 0.5", 1", 2" and 4". and thus act as a 4 bit binary positioning device for positioning the right vacuum bar assembly 470 and left vacuum bar assembly 490 in up to 16 different positions can be selected depending on the cylinder combination used. The left and right positioning pneumatic cylinder assemblies 540 and 542 are preferably operatively connected to the central computer system of the selection and bundling apparatus of the present invention so that during operation of the vacuum section transport carriage 140, the left and right positioning pneumatic cylinder assemblies 540 and 542 can properly set the preferred position for the right and left vacuum bar assemblies 470 and 490 relative to the center vacuum bar assembly 480.
[0061] The significant reason for requiring the right and left vacuum bar assemblies 470 and 490 to be movable relative to the center vacuum bar assembly 480 is that when the vacuum section transport carriage 140 of the present invention is being used in connection with a board sorting and bundling apparatus, the accumulator rows 84 are spaced according to the widest width of flooring the machine is designed to handle. For example, four inch wide flooring would normally require the accumulator rows 84 to be on six inch centers, while three point two five inch flooring would require five point two five inch centers for the accumulator rows 84. This means that in order for the vacuum section transport carriage 140 of the present invention to be able to pick up multiple rows of boards being accumulated within the accumulator rows 84, the distance between the right, center, and left vacuum bar assemblies 470, 480, and 490 must be capable of being adjusted, and this adjustment must be made on the fly in order to permit the multiple rows of boards to be picked up by the vacuum section transport carriage 140 simultaneously without having to drop off each row of boards while permitting the carriage to make a move between picking up individual rows in different locations, thus facilitating the collection of the boards and increasing the efficiency of the unit. Specifically, the ideal form of a picker unit would pick up two or more rows of boards, move those rows of boards into closer transverse proximity to conserve conveyor space, allow for easier compaction of the columns of product, and also because in the preferred embodiment of the sorting and bundling apparatus, the rows coming out of the flipper unit described in related patents will already be close together. The vacuum section transport carriage 140 therefore needs to be able to pick up the rows on six inch or five point two five inch centers so that it may pick up two or three rows at a time, particularly if they happen to be next to one another. These rows would then be moved into adjacent configuration such that the tongue in groove elements of the wood flooring at least partially engage each other, therefore rendering the layer of rows of boards being carried by the vacuum section transport carriage 140 a more compact and cohesive unit. Also, it has been found that the suction pads 489 are excellent for retaining a product thereon during lateral interaction between adjacent rows, such as when the rows of boards being supported by the right, center, and left vacuum bar assemblies 470, 480, and 490 are moved into adjacent contact with one another by the movement of the right and left vacuum bar assemblies 470 and 490 towards the center vacuum bar assembly bar 480. However, the rows of boards are comparatively easily dislodged from the suction pads 489 when vertical forces are applied, such as would be encountered when a row of boards were being lifted upwards via retraction of the pneumatic piston 1000a, 1000b and 1000c to move the vacuum bar support frame 486 into adjacent contact with the main support beam 482 of center vacuum bar assembly 480. If the rows of boards were to interact vertically during that process, it is quite likely that the rows of boards would be dislodged from adjacent ones of the right, center, and left vacuum bar assemblies 470, 480, and 490, thus dislodging the row of boards and dropping it into the accumulator rows 84, which, in all likelihood, would result in the machine having to be shut down until such time as the dislodged boards can be removed and reset within the accumulator rows 84.
[0062] It is to be understood that numerous additions, modifications and substitutions may be made to the vacuum section transport carriage 140 of the present invention which fall within the intended broad scope of the appended claims. For example, the size, shape, and construction materials used in connection with the various elements of the present invention may be modified or changed so long as the functional and operational characteristics of the invention are neither destroyed nor significantly degraded. Furthermore, modification or substitution of various control and drive elements as described herein should be understood to be well within the purview of this disclosure, and such modification or improvements should be understood to be a part of this invention. Finally, although the present invention has been described for use in connection with a board sorting and bundling apparatus, it should be noted, of course, that it may be used for any purpose for which the apparatus described herein is suited, and it is expected that the present invention may be used in connection with other board processing devices found in the prior art.
[0063] Since the preferred bundle size in most flooring mills is 3 rows wide by 4 or 5 layers high, the vacuum suction transport carriage 140 of the present invention is preferably designed to pick up and handle three (3) rows at one time. Thus, one trip of the carriage 140 will place one layer of product onto the bundle. Wider width flooring may be stacked 2 or 1 row wide, but rarely would a bundle have more than 3 rows in a layer. The accumulator rows 84 are spaced according to the widest width of flooring the machine is designed to handle.
For example, 4" wide flooring would normally require the accumulator rows 84 to be on 6"
centers, while 3.25" flooring would require 5.25" centers for the accumulator rows 84.
However, of course, these distances may vary slightly with design details.
Ideally, the rows need to be stacked on the bundles closer together to conserve conveyor space, allow for easier compaction of the columns of product, and also because the rows coming out of the flipper unit, as described later herein, are already close together. The vacuum suction transport carriage 140 therefore needs to be able to pick the rows up on 6" or 5.25"
centers so that it is able to pick up 2 or 3 rows at a time if they happen to be next to each other.
[0064] It should further be noted that the computerized central processor 180 is programmed to give preference to complete rows which are being held in adjacent accumulator rows 84 to take advantage of this feature of the vacuum suction transport carriage 140. Of course, it should be noted that as the present invention will sort boards of only one width at a time, the row centers will not change once they are set by the computerized central processor 180 until the apparatus is cleared and begins sorting boards of a new width. In fact, the row center to center distance is fixed at the time of fabrication whereas the channel width changes for different widths of flooring. This is accomplished by wasting space between the channels.
[0065] One, two or three rows are then picked up by the carriage 140 and the entire layer of two or three rows is then transferred by the carriage 140 to the bundling section 100, as shown in Figures 11-15 where the appropriate selected number of layers are placed atop one another to form the layered bundle of boards, which is usually three to five layers of two to three boards each. The top layer of boards is then deposited in a layer inverting mechanism 120, shown best in Figures 11 and 12, where it is flipped to orientate the bottom side of the layer face up, and the flipped layer is then transferred back to the bundle 300 in order to protect the top face of the finished bundle. Briefly, the layer inverting mechanism 120 includes a board row receiving assembly 122 which receives the top layer of boards and secures them therewithin. The board row receiving assembly 122 then rotates about its longitudinal axis 1800 so that the top layer of boards is inverted with the bottom side of the layer projecting upwards. The board row receiving assembly 122 then releases the top layer of boards, and the vacuum suction transport carriage 140 reengages the top layer of boards to transport it to the top of the bundle being formed in the bundling section 100, and the bundle 300 is then ready for final packaging prior to shipping.
[0066] The bundle 300 is then crammed together by opposing cramming plates 303a and 303b, as shown in Figure 13 and 14, and top press plate 304 which tightly bunch and align the layers of the bundle 300, and the bundle 300 is then wrapped by appropriate securement banding straps 308 to secure the bundle 300 for transport. In the preferred embodiment, the bundling device 302 would include a banding device 306 operative to extend and secure a securement banding strap 308 around the bundle 300 at a series of spaced locations along the length of the bundle 300 as the bundle 300 is moved forwards by a bundle feed conveyor 306 and is held in contact therewith by a tensioning roller 310 which presses on the top layer of the bundle 300 as shown best in Figures 14 and 15. The bundle 300 is then prepared for distribution and shipping thereof as it exits onto a support table 312, as shown best in Figure 16.
[0067] The important features of the present invention is that it is designed to take in a board 200 and determine which accumulating row 84 to deposit the board 200 in, without requiring prior buffering as is necessary with almost all other prior art methods and devices.
In the present invention, the only available storage is in the plurality of accumulator rows 84.
Typically between 16 and 24 rows need to be allocated for each grade, with only 6 or 8 rows needed to accumulate shorts. Rows are not predetermined to handle just one grade, but are dynamically allocated as needed by the sorting algorithm, taking into account the proximity of the bundle conveyors 306 designated to handle the particular grade of board 200. The difficult part of the process is to find a place for each board 200 while forming rows within tolerance and not running out of rows. It has been found, however, that the use of at least sixteen accumulating rows 84 for each grade will permit sorting and accumulating of over ninety to ninety-five percent (90% to 95%) of the boards 200 passing through the apparatus, and the use of more accumulating rows 84 will bring the number of unsorted boards 200 down even more.
[0068] To better understand the overall process of selecting, sorting, and bundling various lengths of boards, an overall view of the method, as shown best in Figures 17-22, will now be described. Once a board 200 enters the infeed of the present invention, it is butted to the inner side of the infeed section and the board then may move on to the grading area unless grading has already taken place.
[0069] In one embodiment of the present invention, each board being carried on the device 10 is assigned to a grader based on the number of personnel available for grading. For example, if there were only a single grader available, he or she would grade each and every board passing through the device, whereas two graders would alternate grading every other board and three graders would each grade every third board, and so on and so forth. Once the board has been graded by the grading personnel, that information is stored in the appropriate register of the slat array and is available to the computer program which associates the particular grade with each and every selected board passing through the device.
[0070] The board then moves underneath the light curtain which determines the length of each piece of board and this information is coordinated by the computing device to enter into the board array so that the computer now associates each particular board with a length and grade in the board array. A shaft encoder and a slat sensor determines the starting point for the lugs and then the positioning and location of where the particular slats are located is known by the computer thereby determining the position of the board within the slat to see if it is at or near the first row of the appropriate grade sorting area as the board travels along the device. Once the board reaches the selected grade sorting area, the sorting algorithm is called by the computing system to determine the location into which the board should be placed.
100711 The sorting algorithms, specifically the optimization subroutines, are shown best in Figures 17-22 as including the overall optimization subroutine and the sorting subroutines for the various attempts to place the board in an accumulating row. As shown best in Figure 17, the optimization subroutine asks a series of yes-no questions to determine the subroutine solution to be called by the program to sort the board into the appropriate row.
As the boards passing through the device are of various lengths, the series of inquiries which must be made by the optimization subroutine are designed to determine the appropriate location for the board in a sorting row and the subroutine begins by asking is this board a one-board solution, which basically is inquiring is this board of sufficient length to occupy an entire row by itself. In a standard seven foot or eight foot long bundle, if the board is within a few inches of the total seven or eight foot length of each row, the board will be a one-board solution and the optimization subroutine then calls the one-board subroutine, as shown in Figure 18. In fact, the one board solution actually checks for a special case that requires the minus tolerance to be relaxed. Consider the following typical scenario: The desired row length is set to 84" and the maximum plus or minus tolerance is set to 3". The shortest board ever produced might be 8" or 9". If the first board in a row is 80", a board between 1" and 7"
would have to be found to complete the row within tolerance. Since no board will ever be produced to complete the row, the single board has to be considered a full row, even though it is shorted than the minimum tolerance. The one-board subroutine is designed to solve this problem, and the subroutine is only used for boards long enough to provide a one-board solution as discussed herein.
[0072] If the board is not a one-board solution, the finish row subroutine shown best in Figure 19 is called, which is designed to find the best row for the board currently being processed to fill the row, i.e. one which is closest to the target length. The optimization subroutine then asks if the board under scrutiny will complete a row and if so the subroutine ends and begins to process the next board in line. If, however, the board will not complete a row, the optimization subroutine calls the best row subroutine which is shown in Figure 20, and the detailed inquiries are disclosed in the flowchart of that figure and further discussion is not deemed necessary.
[0073] The best row subroutine, after running, then returns to the optimization subroutine which inquires if a row was found for the board under scrutiny, and if one has been found, the optimization subroutine ends and then moves on to the next board to be sorted. If, however, a row was not found for that board, the empty row subroutine of Figure 21 is then called which sends the board to any empty row in order to start a new row for the sorting mechanism. The optimization subroutine then again inquires if a row was found for that board, and, if so, the optimization subroutine ends and moves on to the next board in line. If, however, a row was not found for the board, the last resort subroutine shown best in Figure 22 is called which attempts to find the best remaining row for the board to go into.
This is the final attempt used by the optimization subroutine, and in fact by the overall sorting algorithm, to attempt to place the board in a row in the device, although this sorting attempt will continue so long as the board remains in the apparatus, i.e. until the board passes the last possible sorting row. In the unlikely event that a location cannot be found into which the board will fit, however, the board is allowed to exit the end of the machine for manual sorting at a later time and the optimization subroutine is moved on to the next board in line for sorting thereof. In the preferred embodiment, it has been found that with approximately twenty-four rows available for each grade of a board to be sorted, an extremely limited number of boards will need to be sorted after the entire optimization subroutine has been processed, and it is expected that the operator of the present invention will not have to actually manually sort the boards which exit the end of the device, but instead will simply run those boards through the invention again so that they may be properly sorted through application of the sorting algorithm to those boards thereby finding an appropriate row in which those boards may be placed.
[0074] Once the designated row has been determined for a board, the board drops into the appropriate location and is gathered in the proper accumulator row. Once three full rows of a given grade are accumulated, the vacuum carriage previously described removes the rows from the accumulator and places them on the bundle conveyor or on the flipper device as was described previously.
[0075] If the bundle layer is to be the top layer of the bundle, it is pushed into the flipping device, rotated one hundred eighty degrees and pushed back out of the flipper in order to place the bottom of the boards in a "face up" position for transport purposes. The layer is then transported by the vacuum carriage to the bundle conveyor and the completed bundle is compacted horizontally by the cramming mechanism and resulting bundle is then sequenced through the banding device as was described previously. It is believed that this overall view of the "life of a board" should provide valuable assistance to persons wishing to understand operation of the method and apparatus of the invention, and application of the various detailed selecting, sorting and bundling aspects of the present invention to boards passing therethrough should be understood to be disclosed by the above disclosure and through reference to the drawings accompanying this document.
[0076] It is to be understood that numerous additions, modifications and substitutions may be made to the improved board sorting and bundling apparatus and method 10 of the present invention which fall within the intended broad scope of the appended claims. For example, the size, shape, and construction materials used in connection with the present invention may be modified or changed so long as the intended functional characteristics of the present invention are generally maintained. Also, although the infeed section 20, measurement section 40, sorting section 60, accumulating row section 80, bundling sections 100, vacuum suction transport carriage 140 and central processor 180 have been described as including certain particular functional elements and features, modification of these elements and features which do not significantly degrade or destroy the functionality of the various sections should be understood to fall within the intended broad scope of the appended claims.
Finally, although the present invention has been described for use in connection with the sorting and bundling of wood floor boards, it should be noted, of course, that it may be used for any purpose for which the apparatus is suited, and it is expected that the present invention may be used for sorting of other wood board types in the same efficient and safe manner.
[0077] There has therefore been shown and described an improved board sorting and bundling apparatus and method 10 and vacuum suction transport carriage 140 which accomplishes at least all of its intended objectives.
[00551 The vacuum section transport carriage 140 of the present invention is shown best in Figures 23-26 as including a carriage body 141 which includes a main frame 142, including lower carriage frame beams 416a and 416b and upper carriage frame beams 418a and 418b which are connected to and extend between outer frame support plates 420a and 420b. In the preferred embodiment, the carriage body 141 would have dimensions of approximately eight to ten feet in length, two to four feet in width, and two to three feet in height, although the exact dimensions of the carriage body 141 will generally be determined by dimensions of the accumulator row section 80 and accumulator rows 84 over which the vacuum suction transport carriage 140 is traveling, as shown best in Figure 10. Mounted on and extending between the lower carriage frame beams 416a and 416b is the vacuum picker assembly 460 which will be described later in this disclosure.
[0056] Rotatably mounted on the lower portions of the outer frame support plates 420a and 420b are a plurality of carriage roller wheels 422a, 422b, 422c and 422d, which fit within the support rails of the selection bundling apparatus on which the vacuum section transport carriage 140 is mounted, although it should be noted that many different types of carriage roller wheels, slides or other movement-facilitating devices may be used with the present invention so long as the vacuum section transport carriage 140 is able to freely move back and forth on the selection bundling apparatus to pick up and transport rows of boards.
The drive mechanism 424 for the vacuum section transport carriage 140 may be of many different kinds, including providing the vacuum section transport carriage 140 with a self-propulsion unit such as an electric motor which drives the carriage roller wheels 422a-d or generally any other type of propulsion device which is controllable by the central controller computer of the selection bundling apparatus 10, but in the preferred embodiment, it is preferred that the drive mechanism 424 be a chain drive, rack and pinion gear system, timing belts, or another such drive device, depending on the performance preferences desired by the manufacturer and/or user of the present invention. The mechanism further includes a plurality of drive gears 426a and 426b through which the chain drive (as shown in Figure 10) extends. The chain drive would then pass over the main drive gear 428 through which drive shaft 430 extends, and as drive shaft 430 is rotated in response to commands issuing from the central computer system of the selection and bundling apparatus 10 to move the vacuum section transport carriage 140 to the selected accumulator row 84 at which the row of boards is to be picked up for movement to the bundling area 100 of the selection and bundling apparatus 10. In the preferred embodiment, drive shaft 430 would be driven via connection to an electric motor 432 having a bank of capacitors 434 connected thereto for modulating and controlling the electrical current flowing to the electric motor 432 in order to ensure that exceptionally accurate engagement and control of the electric motor 432 is achieved. Of course, there are many different electrical system arrangements which may be used in connection with the present invention which would fulfill the same general functions of the electric motor 432 of the present invention, and such variations and substitutions should be understood to be a part of this disclosure. It should be further noted that in the preferred embodiment the electric motor 432 would be mounted on a mounting frame 436 adjacent the end of drive shaft 430, although the precise mounting design used in connection with the electric motor 432, capacitors 434, and remaining functional elements of the drive system are not particularly critical to the present invention so long as the functional features and performance characteristics are generally maintained.
[0057] An important design feature of the present invention is that the carriage body 141 and in fact the various elements of the main frame 142 are not particularly critical to the functionality of the present invention so long as the carriage body 141 may freely move back and forth above the accumulator rows 84 on the selection and bundling apparatus to access rows of boards which the central computing system has determined need to be picked up and moved to the bundling sections. The truly critical features of the vacuum section transport carriage 140 of the present invention are shown best in Figures 24-26, however; as including the vacuum picker assembly 460 which, in the preferred embodiment, would include a main frame 462 having frame end bars 464a and 464b, each of which are generally L-shaped in cross-sectional shape and inner frame bars 466a and 466b which provide additional structural strength to the main frame 462 of vacuum picker assembly 460, as shown best in Figures 24, 25, and 26. The main operative elements of vacuum picker assembly 460, however, are the three vacuum bar assemblies 470, 480, and 490 which, in the preferred embodiment, are generally identical to one another in function, and therefore the following description of center vacuum bar assembly 480 should be understood to apply equally to vacuum bar assemblies 470 and 490. Center vacuum bar assembly 480 would preferably include a main support beam 482 which is mounted on and extends between the inner frame bars 466a and 466b, as shown best in Figures 24-26. Mounted on the main support beam 482 are a pair of lineal shafts 484a and 484b which keep the suction bars parallel, and there is preferably only one pneumatic cylinder 1000a, 1000b and 1000c, on each of the vacuum bar assemblies 470, 480 and 490, the lower ends of which are connected to a vacuum bar support frame 486.
Mounted on and extending parallel with the vacuum bar support frame 486 is the center vacuum bar 488 itself which, in the preferred embodiment, will be a longitudinally extended bar having a plurality of suction pads 489 mounted on the underside thereof, as shown best in Figure 26. It should be noted that the suction pads 489 may be of many different sizes and shapes, and, in fact, may be formed as a plurality of suction cups should such a configuration be deemed superior for the purposes for which the vacuum section transport carriage 140 is to be used. However, it has been found that a plurality of suction pads 489 having connections to a central vacuum generating device 440 is the preferred structural design for the present invention.
[0058] As was discussed previously, the right vacuum bar assembly 470 and left vacuum bar assembly 490 are generally identical to the center vacuum bar assembly 480 in structural design, however, the significant difference between the right and left vacuum bar assemblies 470 and 490 and center vacuum bar assembly 480 is that the right and left vacuum bar assemblies 470 and 490 are movably mounted on the main frame 462 of vacuum picker assembly 460 so that they may move towards or away from the center vacuum bar assembly 480 in a direction generally perpendicular (specifically, tranversely on the vacuum picker assembly 460) to the center vacuum bar 480, as shown best in Figures 24-26. It should be noted that the precise mechanism by which the right and left vacuum bar assemblies 470 and 490 are moved relative to the center vacuum bar assembly 480 is not critical to the present invention so long as the positioning and movement of the right and left vacuum bar assemblies 470 and 490 relative to the center vacuum bar assembly 480 may be precisely adjusted and quickly and easily configured. In the preferred embodiment shown in Figures 24-26, however, the vacuum bar assembly movement mechanism 500 would include two slide mount bars 502a and 502b on which are slidably mounted the main support beams 472 and 492 of right and left vacuum bar assemblies 470 and 490, as shown best in Figure 25. In the preferred embodiment, the slide mount bars 502a and 502b would be generally cylindrical in cross-sectional shape and would extend generally parallel with the outer and inner frame bars 464a, 464b, 466a, and 466b. The right and left main support beams 472, 482 and 492 would be slidably mounted on the slide mount bars 502a and 502b by bar engagement brackets, with the right and left bar mounting standards 504a, 504b, 506a and 506b being slidably mounted on a respective one of the slide mount bars 502a and 502b on a plurality of lineal bearings 505a, 505b, 507a and 507b so that the right main support beam 472 and left main support beam 492 extend generally parallel with the main support beam 482 of center vacuum bar assembly 480, as shown best in Figure 25.
[0059] To adjust the horizontal positions of the left and right vacuum bar assemblies 470 and 490 relative to center vacuum bar assembly 480, a rotating chain drive positioning assembly 510 is rotatably mounted adjacent outer frame bar 464a with right bar engagement bracket 504a 525b being connected thereto via connection bracket 514 which is connected to chain 512. Likewise, left chain drive positioning assembly 520 is positioned adjacent outer frame bar 464b and the drive chain 522 of left chain drive positioning assembly 520 is operatively connected to left bar engagement bracket 506a of left main support beam 492 via left connection bracket 524, as shown best in Figures 25 and 26. A pair of rotating drive shafts 530 and 532 extend between and connect the opposite ends of the right and left chain drive positioning assemblies 510 and 520, with the connection of first drive shaft 530 to right chain drive positioning assembly 510 being a fixed connection to drive chain 512 and the connection of first drive shaft 530 to left chain drive positioning assembly 520 also being a fixed connection so that the shafts 530 and 532 always rotate in the same direction at the same speed. The right vacuum bar assembly 490 is attached to the top strand of both chains, and the left vacuum bar assembly 470 is attached to the bottom strand of both chains. This arrangement forces the bars to move in opposite directions from the center bar, but still keeps both outside bars equidistant from and parallel to the center bar. This is best shown in Figure 24. In this manner, the horizontal positions of right vacuum bar assembly 470 and left vacuum bar assembly 490 relative to center vacuum bar assembly 480 may be precisely determined and adjusted by engagement of first and second drive shafts 530 and 532 which respectively drive right chain drive positioning assembly 510 and left chain drive positioning assembly 520 to move the right and left main support beams 472 and 492 on slide mount bars 502a and 502b.
[0060] Left and right positioning pneumatic cylinder assemblies 540 and 542 would each include a mounting bracket and a stack of four (4) pnuematic cylinders operatively connected to the right vacuum bar assembly 470 and left vacuum bar assembly 490. The four cylinders are preferably each a different stroke, 0.5", 1", 2" and 4". and thus act as a 4 bit binary positioning device for positioning the right vacuum bar assembly 470 and left vacuum bar assembly 490 in up to 16 different positions can be selected depending on the cylinder combination used. The left and right positioning pneumatic cylinder assemblies 540 and 542 are preferably operatively connected to the central computer system of the selection and bundling apparatus of the present invention so that during operation of the vacuum section transport carriage 140, the left and right positioning pneumatic cylinder assemblies 540 and 542 can properly set the preferred position for the right and left vacuum bar assemblies 470 and 490 relative to the center vacuum bar assembly 480.
[0061] The significant reason for requiring the right and left vacuum bar assemblies 470 and 490 to be movable relative to the center vacuum bar assembly 480 is that when the vacuum section transport carriage 140 of the present invention is being used in connection with a board sorting and bundling apparatus, the accumulator rows 84 are spaced according to the widest width of flooring the machine is designed to handle. For example, four inch wide flooring would normally require the accumulator rows 84 to be on six inch centers, while three point two five inch flooring would require five point two five inch centers for the accumulator rows 84. This means that in order for the vacuum section transport carriage 140 of the present invention to be able to pick up multiple rows of boards being accumulated within the accumulator rows 84, the distance between the right, center, and left vacuum bar assemblies 470, 480, and 490 must be capable of being adjusted, and this adjustment must be made on the fly in order to permit the multiple rows of boards to be picked up by the vacuum section transport carriage 140 simultaneously without having to drop off each row of boards while permitting the carriage to make a move between picking up individual rows in different locations, thus facilitating the collection of the boards and increasing the efficiency of the unit. Specifically, the ideal form of a picker unit would pick up two or more rows of boards, move those rows of boards into closer transverse proximity to conserve conveyor space, allow for easier compaction of the columns of product, and also because in the preferred embodiment of the sorting and bundling apparatus, the rows coming out of the flipper unit described in related patents will already be close together. The vacuum section transport carriage 140 therefore needs to be able to pick up the rows on six inch or five point two five inch centers so that it may pick up two or three rows at a time, particularly if they happen to be next to one another. These rows would then be moved into adjacent configuration such that the tongue in groove elements of the wood flooring at least partially engage each other, therefore rendering the layer of rows of boards being carried by the vacuum section transport carriage 140 a more compact and cohesive unit. Also, it has been found that the suction pads 489 are excellent for retaining a product thereon during lateral interaction between adjacent rows, such as when the rows of boards being supported by the right, center, and left vacuum bar assemblies 470, 480, and 490 are moved into adjacent contact with one another by the movement of the right and left vacuum bar assemblies 470 and 490 towards the center vacuum bar assembly bar 480. However, the rows of boards are comparatively easily dislodged from the suction pads 489 when vertical forces are applied, such as would be encountered when a row of boards were being lifted upwards via retraction of the pneumatic piston 1000a, 1000b and 1000c to move the vacuum bar support frame 486 into adjacent contact with the main support beam 482 of center vacuum bar assembly 480. If the rows of boards were to interact vertically during that process, it is quite likely that the rows of boards would be dislodged from adjacent ones of the right, center, and left vacuum bar assemblies 470, 480, and 490, thus dislodging the row of boards and dropping it into the accumulator rows 84, which, in all likelihood, would result in the machine having to be shut down until such time as the dislodged boards can be removed and reset within the accumulator rows 84.
[0062] It is to be understood that numerous additions, modifications and substitutions may be made to the vacuum section transport carriage 140 of the present invention which fall within the intended broad scope of the appended claims. For example, the size, shape, and construction materials used in connection with the various elements of the present invention may be modified or changed so long as the functional and operational characteristics of the invention are neither destroyed nor significantly degraded. Furthermore, modification or substitution of various control and drive elements as described herein should be understood to be well within the purview of this disclosure, and such modification or improvements should be understood to be a part of this invention. Finally, although the present invention has been described for use in connection with a board sorting and bundling apparatus, it should be noted, of course, that it may be used for any purpose for which the apparatus described herein is suited, and it is expected that the present invention may be used in connection with other board processing devices found in the prior art.
[0063] Since the preferred bundle size in most flooring mills is 3 rows wide by 4 or 5 layers high, the vacuum suction transport carriage 140 of the present invention is preferably designed to pick up and handle three (3) rows at one time. Thus, one trip of the carriage 140 will place one layer of product onto the bundle. Wider width flooring may be stacked 2 or 1 row wide, but rarely would a bundle have more than 3 rows in a layer. The accumulator rows 84 are spaced according to the widest width of flooring the machine is designed to handle.
For example, 4" wide flooring would normally require the accumulator rows 84 to be on 6"
centers, while 3.25" flooring would require 5.25" centers for the accumulator rows 84.
However, of course, these distances may vary slightly with design details.
Ideally, the rows need to be stacked on the bundles closer together to conserve conveyor space, allow for easier compaction of the columns of product, and also because the rows coming out of the flipper unit, as described later herein, are already close together. The vacuum suction transport carriage 140 therefore needs to be able to pick the rows up on 6" or 5.25"
centers so that it is able to pick up 2 or 3 rows at a time if they happen to be next to each other.
[0064] It should further be noted that the computerized central processor 180 is programmed to give preference to complete rows which are being held in adjacent accumulator rows 84 to take advantage of this feature of the vacuum suction transport carriage 140. Of course, it should be noted that as the present invention will sort boards of only one width at a time, the row centers will not change once they are set by the computerized central processor 180 until the apparatus is cleared and begins sorting boards of a new width. In fact, the row center to center distance is fixed at the time of fabrication whereas the channel width changes for different widths of flooring. This is accomplished by wasting space between the channels.
[0065] One, two or three rows are then picked up by the carriage 140 and the entire layer of two or three rows is then transferred by the carriage 140 to the bundling section 100, as shown in Figures 11-15 where the appropriate selected number of layers are placed atop one another to form the layered bundle of boards, which is usually three to five layers of two to three boards each. The top layer of boards is then deposited in a layer inverting mechanism 120, shown best in Figures 11 and 12, where it is flipped to orientate the bottom side of the layer face up, and the flipped layer is then transferred back to the bundle 300 in order to protect the top face of the finished bundle. Briefly, the layer inverting mechanism 120 includes a board row receiving assembly 122 which receives the top layer of boards and secures them therewithin. The board row receiving assembly 122 then rotates about its longitudinal axis 1800 so that the top layer of boards is inverted with the bottom side of the layer projecting upwards. The board row receiving assembly 122 then releases the top layer of boards, and the vacuum suction transport carriage 140 reengages the top layer of boards to transport it to the top of the bundle being formed in the bundling section 100, and the bundle 300 is then ready for final packaging prior to shipping.
[0066] The bundle 300 is then crammed together by opposing cramming plates 303a and 303b, as shown in Figure 13 and 14, and top press plate 304 which tightly bunch and align the layers of the bundle 300, and the bundle 300 is then wrapped by appropriate securement banding straps 308 to secure the bundle 300 for transport. In the preferred embodiment, the bundling device 302 would include a banding device 306 operative to extend and secure a securement banding strap 308 around the bundle 300 at a series of spaced locations along the length of the bundle 300 as the bundle 300 is moved forwards by a bundle feed conveyor 306 and is held in contact therewith by a tensioning roller 310 which presses on the top layer of the bundle 300 as shown best in Figures 14 and 15. The bundle 300 is then prepared for distribution and shipping thereof as it exits onto a support table 312, as shown best in Figure 16.
[0067] The important features of the present invention is that it is designed to take in a board 200 and determine which accumulating row 84 to deposit the board 200 in, without requiring prior buffering as is necessary with almost all other prior art methods and devices.
In the present invention, the only available storage is in the plurality of accumulator rows 84.
Typically between 16 and 24 rows need to be allocated for each grade, with only 6 or 8 rows needed to accumulate shorts. Rows are not predetermined to handle just one grade, but are dynamically allocated as needed by the sorting algorithm, taking into account the proximity of the bundle conveyors 306 designated to handle the particular grade of board 200. The difficult part of the process is to find a place for each board 200 while forming rows within tolerance and not running out of rows. It has been found, however, that the use of at least sixteen accumulating rows 84 for each grade will permit sorting and accumulating of over ninety to ninety-five percent (90% to 95%) of the boards 200 passing through the apparatus, and the use of more accumulating rows 84 will bring the number of unsorted boards 200 down even more.
[0068] To better understand the overall process of selecting, sorting, and bundling various lengths of boards, an overall view of the method, as shown best in Figures 17-22, will now be described. Once a board 200 enters the infeed of the present invention, it is butted to the inner side of the infeed section and the board then may move on to the grading area unless grading has already taken place.
[0069] In one embodiment of the present invention, each board being carried on the device 10 is assigned to a grader based on the number of personnel available for grading. For example, if there were only a single grader available, he or she would grade each and every board passing through the device, whereas two graders would alternate grading every other board and three graders would each grade every third board, and so on and so forth. Once the board has been graded by the grading personnel, that information is stored in the appropriate register of the slat array and is available to the computer program which associates the particular grade with each and every selected board passing through the device.
[0070] The board then moves underneath the light curtain which determines the length of each piece of board and this information is coordinated by the computing device to enter into the board array so that the computer now associates each particular board with a length and grade in the board array. A shaft encoder and a slat sensor determines the starting point for the lugs and then the positioning and location of where the particular slats are located is known by the computer thereby determining the position of the board within the slat to see if it is at or near the first row of the appropriate grade sorting area as the board travels along the device. Once the board reaches the selected grade sorting area, the sorting algorithm is called by the computing system to determine the location into which the board should be placed.
100711 The sorting algorithms, specifically the optimization subroutines, are shown best in Figures 17-22 as including the overall optimization subroutine and the sorting subroutines for the various attempts to place the board in an accumulating row. As shown best in Figure 17, the optimization subroutine asks a series of yes-no questions to determine the subroutine solution to be called by the program to sort the board into the appropriate row.
As the boards passing through the device are of various lengths, the series of inquiries which must be made by the optimization subroutine are designed to determine the appropriate location for the board in a sorting row and the subroutine begins by asking is this board a one-board solution, which basically is inquiring is this board of sufficient length to occupy an entire row by itself. In a standard seven foot or eight foot long bundle, if the board is within a few inches of the total seven or eight foot length of each row, the board will be a one-board solution and the optimization subroutine then calls the one-board subroutine, as shown in Figure 18. In fact, the one board solution actually checks for a special case that requires the minus tolerance to be relaxed. Consider the following typical scenario: The desired row length is set to 84" and the maximum plus or minus tolerance is set to 3". The shortest board ever produced might be 8" or 9". If the first board in a row is 80", a board between 1" and 7"
would have to be found to complete the row within tolerance. Since no board will ever be produced to complete the row, the single board has to be considered a full row, even though it is shorted than the minimum tolerance. The one-board subroutine is designed to solve this problem, and the subroutine is only used for boards long enough to provide a one-board solution as discussed herein.
[0072] If the board is not a one-board solution, the finish row subroutine shown best in Figure 19 is called, which is designed to find the best row for the board currently being processed to fill the row, i.e. one which is closest to the target length. The optimization subroutine then asks if the board under scrutiny will complete a row and if so the subroutine ends and begins to process the next board in line. If, however, the board will not complete a row, the optimization subroutine calls the best row subroutine which is shown in Figure 20, and the detailed inquiries are disclosed in the flowchart of that figure and further discussion is not deemed necessary.
[0073] The best row subroutine, after running, then returns to the optimization subroutine which inquires if a row was found for the board under scrutiny, and if one has been found, the optimization subroutine ends and then moves on to the next board to be sorted. If, however, a row was not found for that board, the empty row subroutine of Figure 21 is then called which sends the board to any empty row in order to start a new row for the sorting mechanism. The optimization subroutine then again inquires if a row was found for that board, and, if so, the optimization subroutine ends and moves on to the next board in line. If, however, a row was not found for the board, the last resort subroutine shown best in Figure 22 is called which attempts to find the best remaining row for the board to go into.
This is the final attempt used by the optimization subroutine, and in fact by the overall sorting algorithm, to attempt to place the board in a row in the device, although this sorting attempt will continue so long as the board remains in the apparatus, i.e. until the board passes the last possible sorting row. In the unlikely event that a location cannot be found into which the board will fit, however, the board is allowed to exit the end of the machine for manual sorting at a later time and the optimization subroutine is moved on to the next board in line for sorting thereof. In the preferred embodiment, it has been found that with approximately twenty-four rows available for each grade of a board to be sorted, an extremely limited number of boards will need to be sorted after the entire optimization subroutine has been processed, and it is expected that the operator of the present invention will not have to actually manually sort the boards which exit the end of the device, but instead will simply run those boards through the invention again so that they may be properly sorted through application of the sorting algorithm to those boards thereby finding an appropriate row in which those boards may be placed.
[0074] Once the designated row has been determined for a board, the board drops into the appropriate location and is gathered in the proper accumulator row. Once three full rows of a given grade are accumulated, the vacuum carriage previously described removes the rows from the accumulator and places them on the bundle conveyor or on the flipper device as was described previously.
[0075] If the bundle layer is to be the top layer of the bundle, it is pushed into the flipping device, rotated one hundred eighty degrees and pushed back out of the flipper in order to place the bottom of the boards in a "face up" position for transport purposes. The layer is then transported by the vacuum carriage to the bundle conveyor and the completed bundle is compacted horizontally by the cramming mechanism and resulting bundle is then sequenced through the banding device as was described previously. It is believed that this overall view of the "life of a board" should provide valuable assistance to persons wishing to understand operation of the method and apparatus of the invention, and application of the various detailed selecting, sorting and bundling aspects of the present invention to boards passing therethrough should be understood to be disclosed by the above disclosure and through reference to the drawings accompanying this document.
[0076] It is to be understood that numerous additions, modifications and substitutions may be made to the improved board sorting and bundling apparatus and method 10 of the present invention which fall within the intended broad scope of the appended claims. For example, the size, shape, and construction materials used in connection with the present invention may be modified or changed so long as the intended functional characteristics of the present invention are generally maintained. Also, although the infeed section 20, measurement section 40, sorting section 60, accumulating row section 80, bundling sections 100, vacuum suction transport carriage 140 and central processor 180 have been described as including certain particular functional elements and features, modification of these elements and features which do not significantly degrade or destroy the functionality of the various sections should be understood to fall within the intended broad scope of the appended claims.
Finally, although the present invention has been described for use in connection with the sorting and bundling of wood floor boards, it should be noted, of course, that it may be used for any purpose for which the apparatus is suited, and it is expected that the present invention may be used for sorting of other wood board types in the same efficient and safe manner.
[0077] There has therefore been shown and described an improved board sorting and bundling apparatus and method 10 and vacuum suction transport carriage 140 which accomplishes at least all of its intended objectives.
Claims (19)
1. A vacuum suction transport carriage operative to interact with an apparatus for selecting and sorting a plurality of random length boards to form at least one row of boards having a total length within a predetermined target length range, said vacuum suction transport carriage comprising:
a movably supported carriage body;
a vacuum suction generating device;
a vacuum picker apparatus mounted on said carriage body, said vacuum picker apparatus including;
a main frame;
at least two vacuum bar assemblies mounted on said main frame, each of said at least two vacuum bar assemblies including;
an extension and retraction device mounted on and extending downwards from said main frame;
a vacuum bar mounted on a lower end of said extension and retraction device, said vacuum bar including a plurality of suction pads connected to said vacuum suction generating device;
at least one of said at least two vacuum bar assemblies being transversely movably mounted on said main frame whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies; and said at least two vacuum bar assemblies operative to each be extended downwards from said main frame via extension of said extension and retraction device to engage boards with said suction pads having suction applied thereto via said vacuum suction generating device for transport thereby, lift the boards via retraction of said extension and retraction device, and move the boards into adjacent proximity via transverse movement of said at least one of said at least two vacuum bar assemblies for transport of the boards.
a movably supported carriage body;
a vacuum suction generating device;
a vacuum picker apparatus mounted on said carriage body, said vacuum picker apparatus including;
a main frame;
at least two vacuum bar assemblies mounted on said main frame, each of said at least two vacuum bar assemblies including;
an extension and retraction device mounted on and extending downwards from said main frame;
a vacuum bar mounted on a lower end of said extension and retraction device, said vacuum bar including a plurality of suction pads connected to said vacuum suction generating device;
at least one of said at least two vacuum bar assemblies being transversely movably mounted on said main frame whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies; and said at least two vacuum bar assemblies operative to each be extended downwards from said main frame via extension of said extension and retraction device to engage boards with said suction pads having suction applied thereto via said vacuum suction generating device for transport thereby, lift the boards via retraction of said extension and retraction device, and move the boards into adjacent proximity via transverse movement of said at least one of said at least two vacuum bar assemblies for transport of the boards.
2. The vacuum suction transport carriage of claim 1 wherein said carriage body further comprises a main frame having a plurality of carriage roller wheels mounted thereon adapted to fit within and roll on support rails of the selection bundling apparatus on which said vacuum section transport carriage is movably mounted.
3. The vacuum suction transport carriage of claim 1 wherein said vacuum suction generating device comprises a vacuum pump.
4. The vacuum suction transport carriage of claim 1 wherein said extension and retraction device on said vacuum picker apparatus comprises a pneumatic cylinder and piston operative to extend and retract said piston thereby raising and lowering said vacuum bar relative to said main frame of said vacuum picker apparatus.
5. The vacuum suction transport carriage of claim 1 wherein said vacuum bar comprises a generally straight longitudinally extended bar.
6. The vacuum suction transport carriage of claim 1 further comprising a rotating chain drive positioning assembly rotatably mounted on said vacuum picker apparatus and operatively connected to at least one of said at least two vacuum bar assemblies for transversely moving said at least one of said at least two vacuum bar assemblies whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies.
7. The vacuum suction transport carriage of claim 1 comprising inner, middle and outer vacuum bar assemblies, said inner and outer vacuum bar assemblies being transversely movably mounted on said vacuum picker assembly whereby transverse movement of said inner and outer vacuum bar assemblies alternatively increases and decreases the transverse distance between said inner, middle and outer vacuum bar assemblies.
8. In combination:
an apparatus for selecting and sorting a plurality of random length boards to form at least one row of boards having a total length within a predetermined target length range including a measurement section operative to support and measure the length of each of the plurality of random length boards, a sorting section including a sorting device operative to sort each of the plurality of boards, an accumulating row section including a plurality of accumulating rows in board transfer connection with said sorting section for accumulating and storing a row of boards selected from the plurality of boards, board row transfer operative to move a row of boards from at least one of said plurality of accumulating rows to a bundling section, said bundling section receiving and retaining rows of boards from said board row transfer device and a central processor operative to command operation of said measurement section, said sorting section, said accumulating row section, said board row transfer device and said bundling section; and said board row transfer device comprising a vacuum suction transport carriage including;
a carriage body movably mounted over said accumulating row section;
a vacuum suction generating device;
a vacuum picker apparatus mounted on said carriage body, said vacuum picker apparatus including;
a main frame;
at least two vacuum bar assemblies mounted on said main frame, each of said at least two vacuum bar assemblies including;
an extension and retraction device mounted on and extending downwards from said main frame;
a vacuum bar mounted on a lower end of said extension and retraction device, said vacuum bar including a plurality of suction pads connected to said vacuum suction generating device;
at least one of said at least two vacuum bar assemblies being transversely movably mounted on said main frame whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies; and said at least two vacuum bar assemblies operative to each be extended downwards from said main frame via extension of said extension and retraction device to engage boards with said suction pads having suction applied thereto via said vacuum suction generating device for transport thereby, lift the boards via retraction of said extension and retraction device, and move the boards into adjacent proximity via transverse movement of said at least one of said at least two vacuum bar assemblies for transport of the boards.
an apparatus for selecting and sorting a plurality of random length boards to form at least one row of boards having a total length within a predetermined target length range including a measurement section operative to support and measure the length of each of the plurality of random length boards, a sorting section including a sorting device operative to sort each of the plurality of boards, an accumulating row section including a plurality of accumulating rows in board transfer connection with said sorting section for accumulating and storing a row of boards selected from the plurality of boards, board row transfer operative to move a row of boards from at least one of said plurality of accumulating rows to a bundling section, said bundling section receiving and retaining rows of boards from said board row transfer device and a central processor operative to command operation of said measurement section, said sorting section, said accumulating row section, said board row transfer device and said bundling section; and said board row transfer device comprising a vacuum suction transport carriage including;
a carriage body movably mounted over said accumulating row section;
a vacuum suction generating device;
a vacuum picker apparatus mounted on said carriage body, said vacuum picker apparatus including;
a main frame;
at least two vacuum bar assemblies mounted on said main frame, each of said at least two vacuum bar assemblies including;
an extension and retraction device mounted on and extending downwards from said main frame;
a vacuum bar mounted on a lower end of said extension and retraction device, said vacuum bar including a plurality of suction pads connected to said vacuum suction generating device;
at least one of said at least two vacuum bar assemblies being transversely movably mounted on said main frame whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies; and said at least two vacuum bar assemblies operative to each be extended downwards from said main frame via extension of said extension and retraction device to engage boards with said suction pads having suction applied thereto via said vacuum suction generating device for transport thereby, lift the boards via retraction of said extension and retraction device, and move the boards into adjacent proximity via transverse movement of said at least one of said at least two vacuum bar assemblies for transport of the boards.
9. The combination of claim 8 wherein said extension and retraction device on said vacuum picker apparatus comprises a pneumatic cylinder and piston operative to extend and retract said piston thereby raising and lowering said vacuum bar relative to said main frame of said vacuum picker apparatus.
10. The combination of claim 8 wherein said vacuum bar comprises a generally straight longitudinally extended bar.
11. The combination of claim 8 further comprising a rotating chain drive positioning assembly rotatably mounted on said vacuum picker apparatus and operatively connected to at least one of said at least two vacuum bar assemblies for transversely moving said at least one of said at least two vacuum bar assemblies whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies.
12. The combination of claim 8 comprising inner, middle and outer vacuum bar assemblies, said inner and outer vacuum bar assemblies being transversely movably mounted on said vacuum picker assembly whereby transverse movement of said inner and outer vacuum bar assemblies alternatively increases and decreases the transverse distance between said inner, middle and outer vacuum bar assemblies.
13. A vacuum suction transport carriage comprising;
a carriage body;
a vacuum suction generating device;
a vacuum picker apparatus mounted on said carriage body, said vacuum picker apparatus including;
a main frame;
at least two vacuum bar assemblies mounted on said main frame, each of said at least two vacuum bar assemblies including;
an extension and retraction device mounted on and extending downwards from said main frame;
a vacuum bar mounted on a lower end of said extension and retraction device, said vacuum bar including a plurality of suction pads connected to said vacuum suction generating device;
at least one of said at least two vacuum bar assemblies being transversely movably mounted on said main frame whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies; and said at least two vacuum bar assemblies operative to each be extended downwards from said main frame via extension of said extension and retraction device for engaging objects with said suction pads having suction applied thereto via said vacuum suction generating device, lift the objects via retraction of said extension and retraction device, and move the objects into adjacent proximity via transverse movement of said at least one of said at least two vacuum bar assemblies.
a carriage body;
a vacuum suction generating device;
a vacuum picker apparatus mounted on said carriage body, said vacuum picker apparatus including;
a main frame;
at least two vacuum bar assemblies mounted on said main frame, each of said at least two vacuum bar assemblies including;
an extension and retraction device mounted on and extending downwards from said main frame;
a vacuum bar mounted on a lower end of said extension and retraction device, said vacuum bar including a plurality of suction pads connected to said vacuum suction generating device;
at least one of said at least two vacuum bar assemblies being transversely movably mounted on said main frame whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies; and said at least two vacuum bar assemblies operative to each be extended downwards from said main frame via extension of said extension and retraction device for engaging objects with said suction pads having suction applied thereto via said vacuum suction generating device, lift the objects via retraction of said extension and retraction device, and move the objects into adjacent proximity via transverse movement of said at least one of said at least two vacuum bar assemblies.
14. The vacuum suction transport carriage of claim 13 wherein said carriage body further comprises a main frame having a plurality of carriage roller wheels mounted thereon adapted to permit rolling movement of said vacuum section transport carriage.
15. The vacuum suction transport carriage of claim 13 wherein said vacuum suction generating device comprises a vacuum pump.
16. The vacuum suction transport carriage of claim 13 wherein said extension and retraction device on said vacuum picker apparatus comprises a pneumatic cylinder and piston operative to extend and retract said piston thereby raising and lowering said vacuum bar relative to said main frame of said vacuum picker apparatus.
17. The vacuum suction transport carriage of claim 13 wherein said vacuum bar comprises a generally straight longitudinally extended bar.
18. The vacuum suction transport carriage of claim 13 further comprising a rotating chain drive positioning assembly rotatably mounted on said vacuum picker apparatus and operatively connected to at least one of said at least two vacuum bar assemblies for transversely moving said at least one of said at least two vacuum bar assemblies whereby transverse movement of said at least one of said at least two vacuum bar assemblies alternatively increases and decreases the transverse distance between said at least two vacuum bar assemblies.
19. The vacuum suction transport carriage of claim 13 comprising inner, middle and outer vacuum bar assemblies, said inner and outer vacuum bar assemblies being transversely movably mounted on said vacuum picker assembly whereby transverse movement of said inner and outer vacuum bar assemblies alternatively increases and decreases the transverse distance between said inner, middle and outer vacuum bar assemblies.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/075,678 | 2008-03-13 | ||
| US12/075,678 US20080223768A1 (en) | 2007-03-13 | 2008-03-13 | Vacuum suction transport carriage for a selection and bundling apparatus for random length materials |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2658278A1 true CA2658278A1 (en) | 2009-09-13 |
Family
ID=41091648
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2658278 Abandoned CA2658278A1 (en) | 2008-03-13 | 2009-03-13 | Vacuum suction transport carriage for a selection and bundling apparatus for random length materials |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2658278A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113677094A (en) * | 2021-07-26 | 2021-11-19 | 江西旭昇电子有限公司 | Feeding device and feeding method for horizontal electroplating of PCB |
| CN113909133A (en) * | 2021-11-08 | 2022-01-11 | 福州大学厦门工艺美术学院 | Intelligent customized furniture sorting device based on radio frequency identification |
-
2009
- 2009-03-13 CA CA 2658278 patent/CA2658278A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113677094A (en) * | 2021-07-26 | 2021-11-19 | 江西旭昇电子有限公司 | Feeding device and feeding method for horizontal electroplating of PCB |
| CN113909133A (en) * | 2021-11-08 | 2022-01-11 | 福州大学厦门工艺美术学院 | Intelligent customized furniture sorting device based on radio frequency identification |
| CN113909133B (en) * | 2021-11-08 | 2023-08-29 | 福州大学厦门工艺美术学院 | Intelligent customized furniture sorting device based on radio frequency identification |
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