IE20010016A1 - A process for manufacturing timber products - Google Patents

Abstract

Raw logs are delivered through a debarking apparatus and then along a machining line where a number of machining operations are carried out for shaping and cutting the log into timber product pieces of desired nominal dimensions. The timber product pieces are then delivered through a sorting station (50) where each timber product piece is scanned (65) to determine the dimensions and quality of the timber piece. Each timber piece is then conveyed to one of a number of collecting strap sets (72), the relevant collecting strap set (72) being associated with the measured dimensions of the timber product piece. When a collecting strap set (72) fills up with timber product pieces, one end of each strap in the set is released for dropping the timber product pieces onto a conveyor (85) below for delivery to a baling apparatus (95) for stacking the timber product pieces on pallets. <Figure 2>

Description

Statements of Invention According to the invention, there is provided a process for manufacturing timber 10 products, comprising the steps: stripping bark from a log in a log debarking apparatus; delivering the stripped log along a log machining line and canying out a desired 15 sequence of machining operations for shaping the log and cutting the log into a plurality of timber product pieces of desired nominal dimensions; delivering timber product pieces singly to a sorting station and conveying each timber piece in turn through the sorting station along a longitudinal product flow 0 path extending between an inlet and an outlet of the sorting station; at the inlet of the sorting station discharging each timber piece onto an alignment conveyor for positioning the timber piece in a desired alignment by urging the timber forwardly and simultaneously sideways against a live fence comprising an endless belt travelling in the same forward direction as the alignment conveyor, the alignment conveyor having a plurality of spaced-apart driven rollers arranged transversely across the product flow path, each roller being mounted at an inclined angle relative to tine direction of travel of timber pieces along the flow path, said rollers urging each timber piece forwardly and 0 simultaneously sidewardly against the live fence, said live fence comprising an endless belt extending vertically upwardly at one side of the driven rollers against which each timber piece is driven by the rollers for aligning inner ends of the timber pieces; OPEN TO PUBLIC INSPECTION UNDER SECTION 28 AND RULE 23 JNL No. HH-L QF - ‘ n , ΙΕοιοο - 2 delivering the aligned timber product piece to an associated grading device and scanning the timber piece for measurement of desired dimensions of the timber product piece; feeding each scanned timber product piece onto a hanger, conveying the timber product piece on the hanger to a selected collecting strap set associated with the particular measured dimensions of the timber product piece, a number of collecting strap sets being provided at the outlet of the sorting station, each collecting strap set being associated with timber product pieces of particular dimensions; each collecting strap set comprising two or more spaced-apart looped straps forming a sling beneath the hanger; the scanning device being connected to a controller which is operatively connected to a deflector arm associated with each strap set; moving a selected deflector arm between an inoperative position and an operative position for knocking the timber product piece from the hanger into the required collecting strap set associated with said measured timber product piece; collecting a plurality of timber product pieces in the collecting strap sets; and when a collecting strap set has collected a desired number of timber product pieces, releasing one end of each strap for dropping the timber product pieces onto an in-feed conveyor for delivery to a baling apparatus.

In one embodiment of the invention, the baling apparatus the process includes: collecting a row of timber product pieces edge to edge on a fork behind a stop arm; dropping the stop arm; advancing the fork over a pallet to position the row of timber pieces over the pallet; moving a stop arm into engagement with an inner end of the row of timber pieces; retracting the fork leaving the row of timber pieces on the pallet; lowering the pallet; repeating the preceding steps a number of times for building up a bale of stacked rows of timber product pieces on the pallet; delivering the pallet to a taping machine for binding the bale on the pallet.

In another embodiment, the process includes:delivering the timber product pieces through a cross-cut saw assembly upstream of the baling apparatus; the cross-cut saw having a plurality of spaced-apart circular saws for cutting each timber piece to a desired length or into a number of smaller timber pieces of desired lengths; aligning each timber piece prior to delivery to the cross-cut saw by urging the timber pieces forwardly and sidewardly on diagonally arranged feed rollers against a live fence comprising an endless belt travelling in a forward direction towards the cross-cut saw for aligning the ends of the timber pieces with one end of the cross-cut saw.

In another embodiment, each circular saw is movable on a support frame between a lowered disengaged position and a raised cutting position. - 4 In a further embodiment, the process includes upstream of the sorting station, delivering the timber product pieces to one or more timber treatment stations for carrying out one or more timber treatment steps on the timber product pieces. The timber treatment steps may typically include drying and/or applying a preservative to the timber product pieces.

In another embodiment, the process includes:feeding timber product pieces from bales of timber product pieces to the sorting station by mounting each bale on a loader at an infeed conveyor upstream of the sorting station, said infeed conveyor for delivering timber product pieces to the inlet of the sorting station, said loader being of L-shaped construction having a base for receiving the bale and an upstanding support at a front side of the base, tilting the loader for inclining the support, advancing the base upwardly along the support for pushing timber product pieces along the support and discharging timber product pieces from a top end of the support for falling under gravity onto the infeed conveyor.

In another embodiment, the process includes:stripping bark from a raw log in the log debarking apparatus by gripping a raw log between a pair of spaced-apart rotating infeed rollers and urging the log forwardly by means of said rotating infeed rollers through a diaphragm cutter blade assembly having a plurality of overlapping cutter blade segments mounted on a earner ring, the cutter blade segments being movable inwardly and outwardly on the ring for defining a generally circular composite cutter blade formed by inner free ends of each blade segment, £ (Η β Ο 18 - 5 engaging said circular cutter blade with an exterior of the log for stripping bark away from the exterior of the log, and downstream of the cutter blade assembly, gripping the stripped log between a 5 pair of rotating discharge rollers for discharging the stripped log from an outlet end of the debarking apparatus.

Detailed Description of the Invention The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:Fig. 1 is a schematic plan view of portion of a production line for manufacturing timber products according to the process of the invention; Fig. 2 is a schematic plan view of a further portion of the production line; Fig. 3 is an elevational view of the production line portion shown in Fig. 2; Fig. 4 is a plan view of portion of the production line of Fig. 2; Fig. 5 is an elevational view of portion of the production line; Fig. 6 is an elevational view of another portion of the production line; Fig. 7 is an elevational view of a further portion of the production line; Fig. 8 is a plan view of portion of the production line; ’ Fig. 9 is an elevational view of another portion of the production line; Fig. 10 is a detail elevational view showing portion of sorting apparatus used in the process; W?® ? 00 t j Fig. 11 is a view similar to Fig. 10 showing the sorting apparatus in another position of use; Fig. 12 is a detail perspective view showing portion of the apparatus; Fig. 13 is a view similar to Fig. 10 showing the apparatus in another position of use; Fig. 14 is another view similar to Fig. 10 showing the apparatus in a further position of use; Fig. 15 is an elevational view similar to Fig. 10 showing the apparatus in another position of use; Fig. 16 is an elevational view of portion of the production line; Fig. 17 is a detail elevational view of a stacker portion of the production line; Fig. 18 is a view similar to Fig. 17, with the stacker shown in another position of use; Fig. 19 is a view similar to Fig. 17, with the stacker in another position of use; Fig. 20 is a view similar to Fig. 17, with the stacker in a further position of use; Fig. 21 is a view similar to Fig. 17, with the stacker in a further position of use; Fig. 22 is an elevational view of portion of the stacker; Fig. 23 is a view similar to Fig. 22, showing another position of use; Fig. 24 is a plan view of a further portion of the production line; - 7 ΙΕ ο ι ο ο ι β Fig. 25 is a detail elevational view of portion of the production line; Fig. 26 is a perspective view of a log debarking apparatus used in the process; Fig. 27 is a detail elevational view of a cutter assembly of the debarking apparatus; and Fig. 28 is a view similar to Fig. 27 showing the cutter assembly in another position of use.

Refenrihg to the drawings, a process and apparatus according to the invention for manufacturing timber products will be described.

Referring initially to Fig. 1, logs are delivered singly by means of a step feeder 10 onto 15 a conveyor 11 for delivery to an inlet of a debarking apparatus 12. As each log travels through the debarking apparatus 12, the bark is stripped from the log and debarked logs are discharged from the debarking apparatus 12 for delivery along a machining line, indicated generally by the reference numeral 14. 0 Each log is conveyed along the machining line 14 and in travelling along the machining line 14, the log passes through a first chipper 15 for cutting material from opposite sides of the log to impart substantially parallel flat opposed side faces to the log.

Downstream of the first chipper 15, a turntable 16 rotates the log through 90°. The log 25 is then delivered through a second chipper 17 for cutting away material from the remaining opposed rounded sides of the log to impart substantially parallel opposed flat side faces to the log which are substantially perpendicular to the previous pair of flat side faces. 0 Next, the log is delivered through a first router 18 for cutting a rebate in each comer of the log, thus removing the rounded comers, so the log will have a generally cruciform section.

The log is then passed through a scale board cutter 19 which parts away scale boards ΙΕΟ 1 00 1 β - 8 of width corresponding to the width of the rebate from opposite sides of the log leaving flat side faces on the log.

Downstream of the scale board cutter 19, a second turntable 20 rotates the log 5 through 90° and then the log is delivered through a second router 21 for cutting rebates along each comer of the log prior to parting scale boards from opposite sides of the log with a scale board cutter.

The log is then delivered through a log divider 22 having a plurality of parallel spaced10 apart cutter blades for dividing the log longitudinally into a number of timber pieces of a preset desired thickness.

Timber pieces from the machining line 14 are delivered along a conveyor 23 having spaced-apart rollers 24 against an end stop 25. Mounted between rollers 24 adjacent . the end stop 25 is an unloader comprising a number of endless chains 26 travelling transversely relative to the conveyor 23. Dogs 27 projecting outwardly of the chains 26 engage and push the timber pieces from the conveyor 23 onto a transfer conveyor 28 which delivers the timber pieces to an infeed conveyor 29.

It is also possible to discharge timber pieces from a bale 30 of timber pieces, which may be pre-treated, for example, kiln dried or treated with a preservative, onto the infeed conveyor 29. The bale 30 is mounted on a loader 31 of L-shaped construction having an upstanding support 32 at a front side of a base 33 on which the bale 30 is received. The loader 31 is tilted about pivot 34 for inclining the support 32 (Fig. 6).

The base 33 can be slid upwardly along the support 32 for pushing timber product pieces along the support 32 and discharging timber product pieces from a top end of the support 32 for falling under gravity onto the infeed conveyor 29. As the base 33 moves upwardly along the support 32, an uppermost layer 35 of timber pieces will fall under gravity to the infeed conveyor 29.

At an outlet end of the infeed conveyor 29, the timber pieces are dropped into a hopper 40. Pivoting arms 42 adjacent an outlet end of the infeed conveyor 29 are movable between a lowered inoperative position and a raised position projecting above the infeed conveyor 29 forming a stop for the timber pieces to prevent - 9 ΙΕ ο ιοο ι $ excessive build up of timber pieces in the hopper 40 as required.

An elevator 45 picks up timber pieces individually from the hopper 40 for delivery to a sorting station 50. The elevator 45 has a number of spaced-apart endless chains 46 with spaced-apart projections 47 on each chain 46 to engage and pick up a single piece of timber from the hopper 40 so that the timber pieces are delivered singly to an inlet of the sorting station 50.

At an inlet of the sorting station 50, each timber piece is discharged onto an alignment conveyor 51 comprising a set of diagonally arranged spaced-apart driven rollers 52 (Fig. 4) which urge each timber piece both forwardly and sidewardly against a live fence 54 comprising an endless belt 55 against which one end of the timber piece abuts. The belt 55 extends vertically upwardly at one side of the driven rollers 52. Each aligned timber piece 56 is delivered to a star turner 58 having a plurality of radial arms 59 between which the timber piece 10 is received for delivery of each timber piece 56 in turn to a grading device 60.

The grading device 60 has a conveyor 61 with upwardly extending lugs 62 which engage and feed each timber piece 56 to a scanning device 65 for measurement of the thickness, width and length of each timber piece 56. The scanning device 65 also measures the quality of the timber piece 56. At an outlet end of the conveyor 61, each timber piece 56 is discharged onto hangers 70 mounted on an endless belt, said hangers 70 carrying the timber piece 56 and depositing the timber piece 56 in one of a number of collecting strap sets 72 (Figs. 9 to 15).

Each strap 72 has a fixed end attached to a swinging arm 73 and a releasable end 74 releasably attached to a fixed anchor mount 75. Mounted on the fixed anchor 75 is a movable arm 76 connected via linkage 77 to an actuating ram 78 which in turn is connected to a controller which operates the arm 76 in response to the sensed characteristics of each timber piece 56 measured at the scanning device 65. Thus, when a timber piece 56, having a particular characteristic, reaches the associated strap 72, the arm 76 moves upwardly to knock it off the hanger 70 for collection between two or more of the straps 72. - 10 IE 0 100 t g The releasable end 74 of the strap 72 has an eye 80 which is held on the anchor 75 by means of a locking bolt 81 (Fig. 12) which slides through an associated eye 82 on the anchor and into the eye 80 on the strap 72. When the strap 72 becomes full, the bolt 81 is retracted by means of a ram, solenoid or the like, to release the end of the strap 72 which drops downwardly releasing the collected timber pieces 56 onto a conveyor 85. At the same time, a reeling device in the arm 73 reels up the strap Ύ2. (Fig. 13). When fully reeled in, the arm 73 pivots upwardly to realign the eye 80 with the associated eye 82 in the anchor 75 and the locking bolt 81 is again advanced through the eyes 80, 82 to secure the strap 72 in position (Fig. 14). Then, the arm 73 swings downwardly (Fig. 15) to reel out portion of the strap 72 for collection of more timber pieces. The weight of the timber pieces 56 is sufficient to pull the strap 72 from the arm 73 as required to fill up the strap 72 again. It will be noted that a number of the sets of straps are provided along a support frame for collection of the various different sizes and grades of timber pieces.

Referring to Figs. 2, 9 and 16, the timber pieces 56 are fed on the conveyor 85 to an elevator conveyor 86 which deposits timber pieces 56 individually onto an in-feed conveyor 87 for delivery to a cross-cut saw assembly 90. Immediately upstream of the cross-cut saw assembly 90, diagonally arranged rollers 91 urge each timber piece forwardly and sidewardly against a live fence 92 for alignment of ends of the timber pieces 56 prior to delivery through the cross-cut saw 90. The cross-cut saw 90 has a plurality of circular saws 93 which are movably mounted on a support for adjusting the spacing between the saws 93 to cut the timber pieces into any desired lengths. Each circular saw 93 is movable on a support frame between a lowered disengaged position and a raised cutting position. Thus, if desired, the timber product pieces may be delivered straight through the cross-cut saw assembly 90 without cutting the timber product pieces.

Referring to Figs. 17 to 23, downstream of the cross-cut saw assembly 90, the cut timber pieces are delivered to a baling apparatus 95. At the baling apparatus 95, a number of timber pieces 56 are collected edge to edge on a fork 96 behind a stop arm 97 (Fig. 17). When the required number of timber pieces 56 has been collected behind the arm 97, the arm 97 is dropped (Fig. 18) and the fork 96 is advanced over a bale 98 positioning the layer of timber pieces 56 on top of the bale 98. When the fork - 11 IE 01 ο ο ι g is fully advanced, a stop arm 100 is pivoted upwardly to engage an inner end of the row of timber pieces 56 (Fig. 19) and the fork 96 is retracted leaving the row of timber pieces 56 on top of the bale 98 (Fig. 20). When the fork 96 has been fully retracted, the stop arm 100 is dropped and the arm 97 is raised (Fig. 21) to collect another row of timber pieces 56 on the fork 96 which is then deposited as a layer in the manner previously described on top of the bale 98.

When a bale 98 has been completed, it is then delivered on a conveyor 120 to a taping machine 122 for binding the timber pieces on the pallet on which the bale is collected.

Referring now to Figs. 26 to 28, the debarking apparatus 12 is shown in more detail. The apparatus has a pair of vertically spaced-apart in-feed rollers 130 between which a raw log is delivered. The rollers 130 grip and feed the log to a stripping station 132 having a diaphragm cutter blade assembly 134 which is shown in more detail in Figs. 27 and 28. The assembly 134 has a set of cutter blades 135 comprising overlapping cutter blade segments mounted on a carrier ring 136. The cutter blades 135 are movable inwardly and outwardly on the ring 136 for defining a generally circular composite cutter blade 137, formed by inner free ends of each blade segment, which engages the bark of the log stripping the bark from the log. The assembly 134 is rotated within the housing with the log being fed through a central opening 138 to strip away the bark from the log. The cutter blades 135 can be moved inwardly or outwardly to adjust the size of the opening 138 to any required size. As the log is delivered through the cutter assembly 134, at an outlet end of the apparatus, a pair of discharge rollers 140 engage and pull the log through the apparatus and discharge the stripped log from the apparatus.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail within the scope of the appended claims.

Claims (6)

1. A process for manufacturing timber products, comprising the steps: stripping bark from a log in a log debarking apparatus; delivering the stripped log along a log machining line and carrying out a desired sequence of machining operations for shaping the log and cutting the log into a plurality of timber product pieces of desired nominal dimensions; delivering timber product pieces singly to a sorting station and conveying each timber piece in tum through the sorting station along a longitudinal product flow path extending between an inlet and an outlet of the sorting station; at the inlet of the sorting station discharging each timber piece onto an alignment conveyor for positioning the timber piece in a desired alignment by urging the timber forwardly and simultaneously sideways against a live fence comprising an endless belt travelling in the same forward direction as the alignment conveyor, the alignment conveyor having a plurality of spaced-apart driven rollers arranged transversely across the product flow path, each roller being mounted at an inclined angle relative to the direction of travel of timber pieces along the flow path, said rollers urging each timber piece forwardly and simultaneously sidewardly against the live fence, said live fence comprising an endless belt extending vertically upwardly at one side of the driven rollers against which each timber piece is driven by the rollers for aligning inner ends of the timber pieces; delivering the aligned timber product piece to an associated grading device and scanning the timber piece for measurement of desired dimensions of the timber product piece; - 13 IPO JOBjg feeding each scanned timber product piece onto a hanger, conveying the timber product piece on the hanger to a selected collecting strap set associated with the particular measured dimensions 5 of the timber product piece, a number of collecting strap sets being provided at the outlet of the sorting station, each collecting strap set being associated with timber product pieces of particular dimensions; each collecting strap set comprising two or more spaced-apart looped 10 straps forming a sling beneath the hanger; the scanning device being connected to a controller which is operatively connected to a deflector arm associated with each strap set; moving a selected deflector arm between an inoperative position and an operative position for knocking the timber product piece from the hanger into the required collecting strap set associated with said measured timber product piece; collecting a plurality of timber product pieces in the collecting strap sets; and when a collecting strap set has collected a desired number of timber 2 5 product pieces, releasing one end of each stiap for dropping the timber product pieces onto an in-feed conveyor for delivery to a baling apparatus.

2. A process as claimed in claim 1 wherein at the baling apparatus the process 30 includes: collecting a row of timber product pieces edge to edge on a fork behind a stop arm; - 14 ΙΕΟ 1Β Ο 19 dropping the stop arm; advancing the fork over a pallet to position the row of timber pieces over the pallet; moving a stop arm into engagement with an inner end of the row of timber pieces; retracting the fork leaving the row of timber pieces on the pallet; lowering the pallet; repeating the preceding steps a number of times for building up a bale of stacked rows of timber product pieces on the pallet; delivering the pallet to a taping machine for binding the bale on the pallet.

3. A process as claimed in claim 1 or claim 2 wherein the process includes: delivering the timber product pieces through a cross-cut saw assembly upstream of the baling apparatus; the cross-cut saw having a plurality of spaced-apart circular saws for cutting each timber piece to a desired length or into a number of smaller timber pieces of desired lengths; aligning each timber piece prior to delivery to the cross-cut saw by urging the timber pieces forwardly and sidewardly on diagonally arranged feed rollers against a live fence comprising an endless belt travelling in a forward direction towards the cross-cut saw for aligning the ends of the timber pieces with one end of the cross-cut saw.

4. A process as claimed in claim 3, wherein each circular saw is movable on a - 15 IP ff 1 ο ο ι β support frame between a lowered disengaged position and a raised cutting position. A process as claimed in any preceding claim, wherein the process includes upstream of the sorting station, delivering the timber product pieces to one or more timber treatment stations for carrying out one or more timber treatment steps on the timber product pieces. A process as claimed in any preceding claim, wherein the process includes:feeding timber product pieces from bales of timber product pieces to the sorting station by mounting each bale on a loader at an infeed conveyor upstream of the sorting station, said infeed conveyor for delivering timber product pieces to the inlet of the sorting station, said loader being of L-shaped construction having a base for receiving the bale and an upstanding support at a front side of the base, tilting the loader for inclining the support, advancing the base upwardly along the support for pushing timber product pieces along the support and discharging timber product pieces from a top end of the support for falling under gravity onto the infeed conveyor. A process as claimed in any preceding claim, wherein the process includes:stripping bark from a raw log in the log debarking apparatus by gripping a raw log between a pair of spaced-apart rotating infeed rollers and urging the log forwardly by means of said rotating infeed rollers through a diaphragm cutter blade assembly having a plurality of overlapping cutter blade segments mounted on a earner ring, the cutter blade - 16 Ε0 108 »ft segments being movable inwardly and outwardly on the ring for defining a generally circular composite cutter blade formed by inner free ends of each blade segment, engaging said circular cutter blade with an exterior of the log for stripping bark away from the exterior of the log, and downstream of the cutter blade assembly, gripping the stripped log between a pair of rotating discharge rollers for discharging the stripped log from an outlet end of the debarking apparatus. A process as claimed in any preceding claim, including the steps: delivering logs individually to a debarking apparatus and stripping the bark from each log in the debarking apparatus; conveying each log through a first chipper for cutting material from opposite sides of the log to impart substantially parallel flat opposed side faces to the log; delivering the log to a second chipper for cutting away material from the remaining opposed rounded faces of the log to impart substantially parallel opposed flat side faces to the log which are substantially perpendicular to the previous pair of flat side faces; delivering the log to a first router for cutting a rebate in each comer of the log so the log will have a generally cruciform section; parting away scale boards from opposite sides of the log leaving flat side faces on the log; delivering the log to a second router for cutting rebates along each comer of the log and parting scale boards from opposite sides of the log; HBO j βο ϊ β delivering the log through a plurality of parallel spaced-apart cutter blades for dividing the log longitudinally into a number of timber product pieces of a preset desired thickness.

5. 9. A process for manufacturing timber products substantially as hereinbefore described with reference to the accompanying drawings.

6. 10. Timber products whenever produced according to the process as claimed in 10 any preceding claim.