Pocket screw and dowel apparatus

Abstract

A pocket screw and dowel apparatus includes a body assembly having a work deck, a clamp assembly, a carriage assembly movably mounted to the body assembly between a first position and a second position, a dowel drill assembly mounted on the carriage assembly for drilling a dowel bore in a workpiece when the carriage assembly is in the first position, a router assembly mounted on the carriage assembly for routing a pocket in the workpiece when the carriage assembly is in the second position, and a pocket drill assembly mounted on the carriage assembly for drilling a pocket bore in the workpiece when the carriage assembly is in the second position. A method of using the pocket screw and dowel apparatus is also disclosed.

Description

POCKET SCREW AND DOWEL APPARATUSBACKGROUND OF INVENTIONField of Invention[oooi] This application relates, in general, to a pocket screw and dowel apparatus and more particularly to apparatus including devices for routing screw pockets in a workpiece, inserting joinery screws therein, drilling dowel bores in the workpiece, and inserting dowels therein, as well as methods for their use.Description of Related Art

[0002] Many cabinet and furniture products are formed from a plurality of wooden, composite or plastic members which are joined together by various fasteners, most usually wood screws. In many instances, the wood screws are positioned in screw pockets or mortises formed adjacent an edge of a board, which edge is then secured to another board by the wood screws.

[0003] The formation of screw pockets can be accomplished using various types of equipment. Some of the most efficient ways of forming screw pockets are set forth in my prior U.S. Patent Nos. 11,045,970, 10,220,540, 9,403,285, 6,877,536, 5,553,645, 5,063,982 and 4,603,719, the entire contents of which is incorporated herein for all purposes by this reference.

[0004] Alternatively, many cabinet and furniture products are formed of such members joined together using wood dowel pins or "dowels." In many instances, dowels are positioned in a first set of dowel bores formed in an edge of board such that a protruding portion of the dowels may also be inserted into corresponding set of second dowel bores in another board to position and secure the boards together.[ooos] Drilling dowel bores and handling dowels can also be accomplished using various types of equipment. For example, U.S. Patent No. 6,494,354 discloses a dowel driving head device and dowel driving machine, and U.S. Patent No. 5,417,264 discloses a dowel transfer station in dowel driving devices.

[0006] Generally, a dedicated machine and / or a dedicated station is required for separate handling of screw pockets and dowels. As such, significant shop space is generally required to accommodate thefootprint of each machine and / or station, as is a significant capital expense for each machine and / or station. In addition, such machines are often quite complex requiring significant setup times to accommodate for different workpieces as well as significant maintenance and upkeep.

[0007] In light of the foregoing, it would be beneficial to have a pocket screw and dowel apparatus including the features and advantages of both pocket screw woodworking equipment and dowel woodworking equipment in a single easy-to-use machine having a small footprint, while overcoming the above and other disadvantages of known pocket-cutting equipment.

[0008] There is an unmet need in the field for less expensive and more rapid means of preparing pocket screw joinery in combination with dowel joinery. The present disclosure meets these and other needs by providing apparatus and methods for doing so.BRIEF SUMMARY

[0009] One aspect of the present invention is directed to a pocket screw and dowel apparatus may include: a body assembly including a work deck upon which a workpiece may be supported; a clamp assembly mounted on the body assembly for securing the workpiece to the work deck; a carriage assembly movably mounted to the body assembly, the carriage assembly movable between a first position and a second position; a dowel drill assembly mounted on the carriage assembly for drilling a dowel bore in an edge of the workpiece when the carriage assembly is in the first position; a router assembly mounted on the carriage assembly for routing a pocket in a planar face of the workpiece adjacent to the edge when the carriage assembly is in the second position; and a pocket drill assembly mounted on the carriage assembly for drilling a pocket bore extending between the edge and the pocket when the carriage assembly is in the second position.[ooio] The carriage assembly may be movable between a first lower position and a second raised position. And the carriage assembly may pivot between the first lower position and the second raised position approximately 20° to 25° about an axis A that is parallel to a planar surface of the work deck.[ooii] The work deck may include a flange against which the workpiece edge is positioned, with the flange including a dowel aperture through which a dowel bit of the dowel drill assembly extends to drill the dowel bore and into which the dowel passes as the dowel is inserted into the dowel bore, and a pocket aperture through which a pocket bit of the pocket drill assembly extends to drill the pocket bore.

[0012] The dowel drill assembly may simultaneously drill a pair of dowel bores, and the flange may include corresponding a pair of dowel bores located on either side of the pocket bore.

[0013] The apparatus may include a plurality of dowel drill assemblies each for simultaneously drilling a pair of dowel bores, a plurality of router assemblies, and a plurality of pocket drill assemblies.

[0014] The apparatus may further include a screw catch assembly mounted on the carriage assembly for receiving and guiding a screw to the pocket when the carriage assembly is in the second position.

[0015] The apparatus may further include a dowel handling assembly mounted on the carriage assembly for receiving and inserting a dowel into the dowel bore when the carriage assembly is in the second position.

[0016] The apparatus may further include a pneumatic indexing valve configured to control configured to control pneumatic actuators in predetermined sequences.

[0017] The body assembly may further include: a first sheet material having an assembly slot having a slot width and slot length, and a fastener hole having a radius R, wherein a slot area of the assembly slot overlaps with a hole area of the fastener hole such that a radius of the hole extends into the slot area of the assembly slot; a second sheet material including an assembly tab having a tab width and a tab length substantially equal to the slot width and slot length respectively, the assembly tab being inserted into the assembly slot, and the assembly tab has a tab surface facing the fastener hole; and a threaded fastener having external threads, the threaded fastener treaded into the fastener hole engaging with and deforming the tab surface to mechanically secure the threaded fastener to the assembly tab, and in turn secure the first sheet material to the second sheet material.

[0018] The first sheet material may include at least three assembly slots spaced along a first curve, and the second sheet material may include at least three assembly tabs, wherein the second sheet material bowed along a second curve that is complementary in shape the first curve creating a non-linear abutting interface between the first sheet material and the second sheet material.

[0019] The apparatus may further include: a ratcheting indexer rotatable about a valve axis A and having a plurality of indexed settings, the indexer including an inlet located on a radius R from the valve axis, the inlet allowing pressured air to flow through the indexer; an upper plate including a plurality of apertures radially spaced about the valve axis A and along the radius R, each of the plurality of apertures corresponding to a respective setting of the plurality of indexed settings; a valve plate including aplurality of passageways, each having a first end and a second end, each first end radially spaced about the valve axis A and along the radius R, each first end corresponding to a respective one of the plurality of apertures, and each second end being spaced from any adjacent second ends; and a lower plate including a plurality of outlets, each aligned with a respective second end and in fluid communication with a respective one of the plurality of passageways; wherein the inlet is fluidly connected to a respective one of the plurality of outlets depending upon which indexed setting the indexer is positioned; and wherein the indexer, the upper plate, the valve plate, and the lower plate are all formed of planer sheet materials, and wherein the indexer abuts against the upper plate, the upper plate abuts against the valve plate, and the valve plate abuts against the lower plate.

[0020] Another aspect of the present invention is directed to a body assembly structurally supporting components of an apparatus may include: a first sheet material having an assembly slot having a slot width and slot length, and a fastener hole having a radius R, wherein a slot area of the assembly slot overlaps with a hole area of the fastener hole such that a radius of the hole extends into the slot area of the assembly slot; a second sheet material including an assembly tab having a tab width and a tab length substantially equal to the slot width and slot length respectively, the assembly tab being inserted into the assembly slot, and the assembly tab has a tab surface facing the fastener hole; and a threaded fastener having external threads, the threaded fastener treaded into the fastener hole engaging with and deforming the tab surface to mechanically secure the threaded fastener to the assembly tab, and in turn secure the first sheet material to the second sheet material.

[0021] The first sheet material may include at least three assembly slots spaced along a first curve, and the second sheet material may include at least three assembly tabs, wherein the second sheet material bowed along a second curve that is complementary in shape the first curve creating a non-linear abutting interface between the first sheet material and the second sheet material.

[0022] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a perspective view of an exemplary pocket screw and dowel apparatus in accordance with various inventive aspects.

[0024] FIG. 2A is a perspective view showing a workpiece clamped down on a work deck of the apparatus of FIG. 1, the apparatus shown with a portion of the work deck removed.

[0025] FIG. 2B is an enlarged perspective of an exemplary workpiece that has been processed and provided with screw pockets and dowels by the apparatus of FIG. 1.

[0026] FIG. 3 is a rear perspective view of the apparatus of FIG. 1 with a side body panel removed showing various components of the apparatus.

[0027] FIG. 4 is a cross-sectional view of various components of the apparatus of FIG. 1, the view showing certain components of the apparatus mounted on a movable carriage assembly including components clamping the workpiece to the work deck, the view being along a "dowel" axis of the apparatus.

[0028] FIG. 5 is a cross-sectional view similar to FIG. 4 showing a dowel drill forming a dowel bore in the workpiece.

[0029] FIG. 6 is a cross-sectional view similar to FIG. 5 showing the carriage in a second raised position.

[0030] FIG. 7 is a cross-sectional view similar to FIG. 6, but along a "pocket" axis of the apparatus, showing a router assembly in a deployed position routing a pocket in the workpiece.

[0031] FIG. 8 is a cross-sectional view similar to FIG. 7 showing a screw delivered to a screw catch assembly mounted on the router assembly in its deployed position.

[0032] FIG. 9 is a cross-sectional view similar to FIG. 8, but along the "dowel" axis, showing a dowel delivered to a dowel receiver.

[0033] FIG. 10 is a cross-sectional view similar to FIG. 9 showing the dowel dropped down to a staged position within the dowel receiver.

[0034] FIG. 11 is a cross-sectional view similar to FIG. 10, but along the pocket axis, showing the screw catch assembly and router assembly in its retracted position.

[0035] FIG. 12 is a cross-sectional view similar to FIG. 11, but along the dowel axis, showing a dowel driver inserting the dowel into the dowel bore of the workpiece.

[0036] FIG. 13 is a cross-sectional view similar to FIG. 12, but along the pocket axis, showing a pocket drill in its deployed position drilling a pocket bore in the workpiece.

[0037] FIG. 14 is a cross-sectional view similar to FIG. 13 showing the pocket drill returned to its retracted position.

[0038] FIG. 15 is a cross-sectional view similar to FIG. 14 showing the router assembly in its retracted position and the screw catch assembly in a deployed position.

[0039] FIG. 16 is a cross-sectional view similar to FIG. 15 showing the router assembly moved to an intermediate position to insert the screw on the deployed screw catch into the pocket.

[0040] FIG. 17 is a cross-sectional view similar to FIG. 16 showing the router assembly and the screw catch returned to their retracted positions after the screw has been inserted in the pocket.

[0041] FIG. 18A is an exploded view of a pneumatic indexing valve shown in FIG. 3, the exploded view showing details of certain components thereof.

[0042] FIG. 18B is a view of the underside of a lower plate of FIG. 18A.

[0043] FIG. 19A is an enlarged detail view of the housing assembly of FIG. 2A showing assembly tabs and assembly slots for securing together structural components of the housing assembly.

[0044] FIG. 19B is an exploded view of FIG. 19A.DETAILED DESCRIPTION

[0045] Reference will now be made in detail to various embodiments of present inventions, examples of which are illustrated in the accompanying drawings and described below. While the inventions will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the inventions to those exemplary embodiments. On the contrary, the inventions are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents, and other embodiments, which may be included within the spirit and scope of the inventions as defined by the appended claims.

[0046] Turning now to the drawings, wherein like components are designated by like reference numerals throughout the various figures, attention is directed to FIG. 1 which illustrates a pocket screw and dowel apparatus 20 in accordance with various inventive aspects.

[0047] As can be seen in from the various figures, the screw and dowel apparatus generally includes a body assembly 22, a clamp assembly 23 for securing a workpiece 24 to a work deck 26, a movable carriage assembly 27, a dowel drill assembly 28 for drilling dowel bores 29 in an edge 31 of the workpiece, a router assembly 32 for routing pockets 33 in a planar face 35 of the workpiece adjacent to the edge, a screw catch assembly 36 for catching and guiding a screw fastener 37 to the routed pockets, a dowel handling assembly 39 for receiving and inserting dowels 40 into the dowel bores, and a pocket drill assembly 41 for drilling pocket bores 42 extending between the edge and the pocket. In various embodiments, the screw and dowel apparatus may include a pneumatic indexing valve 44 configured to control various pneumatic actuators for selectively moving various components of the apparatus in predetermined sequences.

[0048] As shown in FIG. 1, the pocket screw and dowel apparatus has a generally upright configuration allowing an operator to manually load a joinery member, that is a board to be adapted for connection with another board, into the machine thus allowing multiple screw pockets and dowel bores be formed, with screws and dowels being preloaded into their respective screw pockets and dowel bores without further manual intervention. For convenience, the joinery member will be referred to as a "workpiece" throughout the present description.

[0049] In accordance with various inventive aspects, such a screw and dowel machine may be configured to form three pairs of dowel bores, form five screw pockets and their corresponding pocket screw bores, preload dowels into each of the formed dowel bores, and preload a screw fastener into the corresponding screw pockets in under twenty seconds. Such preloading of dowels and screw fasteners into a joinery member allows it to be shipped flat and stacked with other joinery members thus facilitating shipping and ultimate assembly.[ooso] As shown in FIG. 1, the housing assembly may primarily be formed with plate and sheet materials. For example, the housing assembly may include left and right plate metal side panels 45 that are interconnected by one or more transversely extending sheet members 46.[oosi] In various embodiments, the housing assembly is primarily formed of plate metal plate and sheet metal, cut and bent into shape. For example, the profile of the side panels and / or sheet members may be cut by laser or water-jet and bent into shape. For example, various metal-bending technologies may beutilized to precisely bend the housing, including but not limited to those discussed in my prior U.S. Patent Nos. 6,481,259, 7,152,450, 7,222,511, 7,263,869, 7,350,390,7,350,390, 7,354,639, 7,354,639, and 7,440,874, the entire contents of which is incorporated herein for all purposes by this reference. Alternatively, the profile and shape of the housing may be formed by stamping, molding, and / or other suitable fabrication means. In various embodiments, various gauges of stainless steel sheets may be utilized including but not limited to lOga, 12ga, and 16ga, and / or various gauges of blue steel may be utilized including but not limited to 0.06" martensite. One will appreciate that the panels and sheet members may be formed of other suitable materials, including but not limited to other metals, plastics, composites, and / or other suitable materials.

[0052] In the illustrated embodiment, the transverse sheet members may be bowed or arched upon assembly with the side panels. For example, the sheet members may include assembly tabs 48 (see FIG. 19B) that are inserted into assembly slots 49 formed in the side panels in an arcuate fashion (see FIG. 2A) to cause the sheet members to bow or arch upon assembly with the side panels, bowing or arching to a degree that does not fold or crease the sheet member. The resulting curved shape of the sheet members shown in FIG. 3 not only provides for greater structural integrity of the sheet member, the curved shape also creates a nonlinear abutting interface between the sheet material and the side panels that preventing angular flexing between the two, such flexing being common along a conventional linear joint. One will appreciate that all transverse sheet members need not be bowed or arched - having one or more (but not all) bowed / arched members may provide suitable structural integrity to the overall body assembly, such that other members may be planer without significantly affecting structural integrity. One will also appreciate that other framework may be utilized to stiffen and strengthen the housing assembly as desired.

[0053] As shown in FIG. 19A and FIG. 19B, the tab / slot configuration may include a slot having a fastener hole into which a threaded fastener 50 is screwed while the tab is in the slot, thus mechanically locking the tab in its corresponding slot. Provided that the fastener thread is harder than the tab, and / or the fastener is a self-threading fastener, internal threads may be formed on the tab, thus contributing to a mechanical lock between the tab and its slot without the need for a nut or other internally-threaded fastener. Although a flat-headed fastener is shown, one will appreciate that Phillips, Allen, Torx, Robertson, or other suitable headed fasteners may be utilized.

[0054] One will appreciate that some transverse sheet members may be readily removable to provide greater access to the components of the apparatus. For example, sheet member 46' shown in FIG. 1 has been removed from the apparatus as shown in FIG. 2A providing a clear view of the clamp assembly therein. Similarly, a portion of the work deck 26' has been removed providing a partial view of the carriage assembly below.

[0055] In various embodiments, body assembly 22 supports work deck 26 as shown in FIG. 1. The work deck support includes flange 52 against which an edge of a workpiece may be positioned. The flange has a number of dowel apertures 53 through which a dowel drill bit may pass to drill a dowel bore into the edge of the workpiece, and a number of pocket apertures 54 through which a pocket drill bit may pass to drill a pocket bore into the edge of the workpiece. The dowel aperture also provides access through the flange for the insertion of dowels into the dowel bore while the workpiece is positioned against the flange, as discussed below. The work deck may also include a number of router slots 55 through which a router bit may pass to rout a pocket into a lower planar face or underside of the workpiece. The slot also provides access through the work deck for the insertion of screws into the pocket while the workpiece is positioned on the work deck against the flange. As shown in FIG. 1, the corresponding pocket apertures and pocket slots may be connected, but one will appreciate that they need not be connected.

[0056] With reference to FIG. 2A, clamp assembly 23 is affixed with respect to the body assembly 22 and includes a plurality of clamp feet 57 and corresponding clamp actuators 58. In the illustrated embodiment, the clamp actuator includes a pneumatic cylinder to press the clamp feet downward to secure the workpiece in place. One will appreciate that other suitable clamp means may be utilized to secure the workpiece to the work deck.

[0057] One or more stop assemblies 59 may be provided to correctly position an end of a workpiece relative to the flange such that the dowel and pocket bores are formed at a suitable distance from the end of the workpiece. The stop assembly may be in the form of a pivoting stop that is manually moved from a retracted position to the deployed stop position shown in FIG. 2A, or it may have a pneumatic or other actuator to automatically position the stop.

[0058] In addition, a measuring device 61 may be provided to measure the length of the workpiece. The measuring device may include a laser length sensor or other suitable means to determine the length. The measuring device may measure the length so that an appropriate number of clamp, dowel drill, router, and pocket drill assemblies may be actuated. For example, if the measuring device determines that the length of the workpiece does not extend the full length of the work deck, actuation of the assemblies may be limited to only those that fall with the length of the workpiece, thus preventing drill bits and / or router bits extending into free space beyond the length of the workpiece and possibly injuring an operator, and thus preventing dowels and screws from shooting out beyond the length of the workpiece.

[0059] The body assembly also movably supports carriage assembly 27, which in turn, supports various components such that they can be moved relative to a workpiece that is clamped down on the work deck. For example, the carriage assembly has a first position in which dowel drill assembly 28 is aligned with respect to the workpiece edge for drilling dowel bores (FIG. 5), and a second position in which routerassembly 32 is positioned to rout a pocket into the workpiece (FIG. 7), and in which pocket drill assembly 41 is aligned with the workpiece edge to drill pocket bores (FIG. 13), as will be discussed in greater detail below. One will appreciate that the movable carriage configuration may be particularly well suited for use in dedicated dowel machines and / or in dedicated pocket screw machines.

[0060] The carriage assembly may be pivotally mounted with respect to the housing assembly. For example, carriage assembly 27 is affixed to opposing swing members 62 that are pivotally mounted to the side panels about axis A (see, e.g., FIG. 2A and FIG. 3), which axis is parallel to both the work deck 26 and its flange 52, as well as the workpiece positioned thereon. One will appreciate that the axis need not be coplanar with either the work deck or the flange, but the axis will be parallel to the intersection of the two thus providing provide proper positioning of the various assemblies with respect to workpiece while the carriage assembly is in its first and second positions.

[0061] The carriage assembly may be affixed to swing members 62 by pins 63 or other suitable structure that extend through arcuate openings of the side panels. Such configuration allows the carriage assembly to pivot through a desired swing angle unimpeded by the side panels.

[0062] In various embodiments, the carriage assembly may be formed by a sheet metal casing 65 partially wrapped around multiple carriage partitions 66 thus providing the casing with a curved profile extending transverse to the housing assembly. The curved profile of the casing essentially forms a beam upon which various components may be mounted to move with the carriage assembly.

[0063] Apertures in the casing allow portions of the partitions to extend therethrough and provide mounting structure for various components. For example, a leg 67 may be provided to which router assemblies 32 are pivotally mounted about axis B, and / or a mounting tab 68 may be provided to which other structure may be mounted, such as partition extensions 70 shown in FIG. 3 and described in greater detail below.

[0064] As will also be described in greater detail below, the carriage assembly may be configured to move between a first lower position (see, e.g., FIG. 4) and a second raised position (see, e.g., FIG. 6) in order to position various components relative to workpiece 24 mounted on work deck 26. In the illustrated embodiment, the carriage assembly pivots approximately 20° to 25° between the first and second positions. One or more actuators may be provided to move the carriage assembly. For example, one or more pneumatic lift cylinders 71 may be provided to pivot the carriage assembly relative to the body assembly. One will appreciate that other suitable actuators may be utilized.

[0065] The dowel drill, router, and pocket drill assemblies are all movably mounted on the carriage assembly. For example, the drill assemblies may have slide supports 72 and slide actuators 74 to move between retracted and deployed positions, as discussed below (see, e.g., movement of dowel drill assembly 28 between FIG. 4 and FIG. 5). And the router assemblies may have pivot supports 75 and pivot actuators to move between retracted, intermediate, and deployed positions, as also discussed below. In various embodiments, the actuators are pneumatic, but one will appreciate that various actuators may be utilized. One will appreciate that the drill and router assemblies generally include otherwise conventional features, such as drill and router bits for cutting into wooden workpieces, and motors for driving the bits.

[0066] The screw and dowel apparatus may be provided with catch assembly 36 to supply screws for insertion into the routed pockets 33 (FIG. 8). Screw delivery systems are described in my prior U.S. Patent Nos. 9,403,285 and 6,877,536, the entire contents of which is incorporated herein for all purposes by this reference. As such, one will appreciate that screws may be delivered through a screw feeder tube 76 in an otherwise conventional manner. In accordance with various inventive aspects, catch assembly 36 is mounted on the carriage assembly for receiving a screw from the screw feeder tube and guiding the screw to a routed pocket.

[0067] The catch assembly includes an extendable arm 78 that is mounted on router assembly 32 such that it may pivot with the router assembly between its deployed position (see, e.g., FIG. 10), to its retracted position (see, e.g., FIG. 11), and to its intermediate position (see FIG. 16). The extendable arm is configured to move from a lower retracted position (see, e.g., FIG. 14) to a raised extended position (see, e.g., FIG. 15). In various embodiments, a pneumatic linear actuator may be utilized to provide such motion. One will appreciate that various linear actuators may be utilized in an otherwise conventional manner to provide such motion.

[0068] The extendable arm includes a magnet 79 mounted at its upper end to catch and hold the delivered screw on the extendable arm as it moves with the router assembly. When a screw is magnetically held on the extendable arm as the router assembly pivots from its retracted position to its deployed position, the tip of the screw extends through pocket 33 and engages pocket bore 42 in the router assembly's intermediate position, as shown in FIG. 16. In various embodiments, it is the engagement of the screw with the pocket bore that limits motion of the router assembly to the intermediate position. As the router assembly returns to its retracted position, frictional or other mechanical engagement of the screw with the pocket bore overcomes the magnetic hold of the catch assembly thus leaving the screw positioned within the pocket.

[0069] The pocket screw and dowel apparatus may be provided with dowel handling apparatus 39 to receive and insert a dowel into dowel bore 29 (see, e.g., FIG. 9). Dowel delivery systems are generally known, and one will appreciate that dowels may be delivered through tubing using compressed air in an otherwise conventional manner. In accordance with various inventive aspects, handling assembly 39 is mounted on the carriage assembly and includes a dowel receiver 80 having a two-level chamber. An upper level of the chamber receives a dowel that hits an angled wall in a delivered position, as shown in FIG. 9. The dowel then drops to a staging position on a lower position of the chamber, as shown in FIG. 10, allowing an insertion rod 81 to extend through the dowel receiver and push the dowel into a dowel bore as shown in FIG. 12.

[0070] One will appreciate that a dowel glue assembly may also be provided to insert glue into the dowel bore before a dowel is inserted therein, or that the dowels may themselves be pre-glued dowels in which water may be sprayed into the dowel bore before a dowel is inserted, both of which are otherwise conventional.

[0071] A control unit (CU) may be provided to control the various actuators such that they operate in desired sequences. The control unit generally includes one or more processors and memory, with the processor(s) being configured to run instructions or software for performing various steps. For example, programmable logic modules such as the LOGO products offered by Seimens AG may be programed to control the apparatus in a manner that is illustrated by FIG. 4 to FIG. 17.

[0072] As shown in FIG. 3, the screw and dowel apparatus includes a pneumatic indexing valve 44. The valve is mounted to and movable with the carriage assembly. A plurality of partition extensions 70 may be provided to affix the valve to carriage partitions 66 of the carriage assembly. One will appreciate that the valve need not be mounted to move with the carriage assembly, but such configuration has various benefits including simplified routing of compressed air lines to the various pneumatic actuators, most of which also move with the carriage assembly.

[0073] As shown in FIG. 18A, the valve includes a ratcheting indexer 83 having a pneumatic inlet 84 allowing pressured air provided by a conventional compressed air line to flow therethrough and selectively through one aperture in upper plate 85. In turn, the pressurized air flows into and through a corresponding passageway of a valve plate 87. As can be seen in FIG. 3, and FIG. 18A, the valve plate also serves as the structural support of the valve. The valve plate is mounted to and movable with the carriage assembly via partition extensions 70 (FIG. 3). The various passageways of the valve plate interconnect the apertures of upper plate 85 with corresponding apertures of a lower plate 88. Theapertures of the lower plate are provided with respective pneumatic outlets 89, which in turn, are fluidly and operably connected via compressed air lines to various pneumatic actuators of the above assemblies.

[0074] Indexer 83 is a ratchet gear having seven positions or settings, six of which correspond to the pneumatic outlets of the lower plate, and one corresponds to an "off" position in which there is no corresponding aperture in the upper plate and no corresponding passageway in the valve plate. The indexer is sequentially moved to each position by a linear actuator 91 and held in each position by a pawl 92 such that the indexer only moves in a desired direction and stops at one of several predetermined positions. A retaining plate 93, bearings 94, and fasteners 96 hold the ratcheting indexer, upper plate and lower plate to the valve plate while allowing the ratcheting indexer to rotate.

[0075] In the illustrated embodiment, the valve includes two ratchet gears thus providing twelve settings during which pressurized air may be sequentially delivered to one or more actuators. One will appreciate that one, two, three or more indexers with various positions or settings may be used to provide a preferred number of settings.

[0076] In accordance with various inventive aspects, the ratcheting indexer, the valve plate, and the upper and lower plates are all formed of metal plate and / or sheet metal. The flat surfaces of such metal plate and sheet metal abutting against one another may provide a sufficient fluid barrier that prevents significant air leakage without the need for additional seals. As such, the described valve provides for an inexpensive means to sequentially control pneumatic actuator steps that is easy to set up and requires little maintenance.

[0077] One exemplary method of operating the screw and dowel apparatus in accordance with various inventive aspects can now be described. The exemplary method begins with an operator manually placing a workpiece 24 upon work deck 26. The workpiece may then be secured to the work deck by clamp assembly 23, as shown in FIG. 4. A dowel drill assembly may then drill a dowel bore in the workpiece as shown in FIG. 5.

[0078] As noted above, FIG. 4 is a cross-sectional view along a "dowel" axis, that is, a cross-sectional view that extends through the longitudinal drill bit axis of a corresponding of dowel drill assembly and along the axis of a corresponding inserted dowel. In contrast, FIG. 6 is a cross-sectional view along a "pocket" axis, that is, a cross-sectional view that extends through the router bit axis of a corresponding router assembly and along the longitudinal axis of a routed pocket and the corresponding pocket bore.

[0079] Carriage assembly 27 may then move to a second raised position as shown in FIG. 6. Router assembly 32 may then move to a deployed position routing a pocket in the workpiece, as shown in FIG. 7. While in the deployed position, screw 37 may be delivered to catch assembly 36 mounted on the router assembly, as shown in FIG. 8.

[0080] A dowel may be delivered to dowel receiver 80, as shown in FIG. 9. The dowel may then drop down to a staged position within the dowel receiver, as shown in FIG. 10.

[0081] Router assembly 32 and catch assembly may then move to their retracted positions, as shown in FIG. 11.

[0082] A dowel driver may then insert the dowel 40 into the dowel bore of the workpiece, as shown in FIG. 12.

[0083] A pocket drill may then move to its deployed position to drill a pocket bore in the workpiece, as shown in FIG. 13. The pocket drill may then return to its retracted position, as shown in FIG. 14.

[0084] While router assembly is in its retracted position, an extendable arm 78 of the catch assembly may move to its deployed position, as shown in FIG. 15. The router assembly may then move to an intermediate position inserting the screw on the deployed extendable arm 78 into the pocket, as shown in FIG. 16. The router assembly and the catch assembly may then return to their retracted positions after the screw has been inserted in the pocket, as shown in FIG. 17. And the sequence may again be repeated on another workpiece.

[0085] One will appreciate that the sequence need not be performed in this exact order. For example, the pocket bore drilling may be accomplished before or after the dowel insertion, etc. Nonetheless, the illustrated sequence is particularly well suited for a compact design in which the various components may move without contacting other components that may share common space when deployed. For example, the router bit, the pocket drill bit, and the extension arm all occupy common space within the pocket and thus should not be deployed simultaneously.

[0086] For convenience in explanation and accurate definition in the appended claims, the terms"upper", "downward" or "lower", and the like are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.

[0087] The foregoing descriptions of specific exemplary embodiments of the present inventions have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the inventions to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the inventions and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present inventions, as well as various alternatives and modifications thereof. It is intended that the scope of the inventions be defined by the Claims appended hereto and their equivalents.

Claims

WHAT IS CLAIMED IS:

1. A pocket screw and dowel apparatus comprising: a body assembly including a work deck upon which a workpiece may be supported; a clamp assembly mounted on the body assembly for securing the workpiece to the work deck; a carriage assembly movably mounted to the body assembly, the carriage assembly movable between a first position and a second position; a dowel drill assembly mounted on the carriage assembly for drilling a dowel bore in an edge of the workpiece when the carriage assembly is in the first position; a router assembly mounted on the carriage assembly for routing a pocket in a planar face of the workpiece adjacent to the edge when the carriage assembly is in the second position; and a pocket drill assembly mounted on the carriage assembly for drilling a pocket bore extending between the edge and the pocket when the carriage assembly is in the second position.

2. The pocket screw and dowel apparatus according to claim 1, wherein the carriage assembly is movable between a first lower position and a second raised position.

3. The pocket screw and dowel apparatus according to claim 2, wherein the carriage assembly pivots between the first lower position and the second raised position, and pivots about approximately 20° to 25° about an axis A that is parallel to a planar surface of the work deck.

4. The pocket screw and dowel apparatus according to claim 1, wherein the work deck includes a flange against which the workpiece edge is positioned, the flange including a dowel aperture through which a dowel bit of the dowel drill assembly extends to drill the dowel bore and into which the dowel passes as the dowel is inserted into the dowel bore, and a pocket aperture through which a pocket bit of the pocket drill assembly extends to drill the pocket bore.

5. The pocket screw and dowel apparatus according to claim 1, wherein the dowel drill assembly simultaneously drills a pair of dowel bores, and the flange includes corresponding pair of dowel bores located on either side of the pocket bore.

6. The pocket screw and dowel apparatus according to claim 1, wherein the apparatus comprises a plurality of dowel drill assemblies each for simultaneously drilling a pair of dowel bores, a plurality of router assemblies, and a plurality of pocket drill assemblies.

7. The pocket screw and dowel apparatus according to claim 1, wherein the apparatus further comprises a screw catch assembly mounted on the carriage assembly for receiving and guiding a screw to the pocket when the carriage assembly is in the second position.

8. The pocket screw and dowel apparatus according to claim 1, wherein the apparatus further comprises a dowel handling assembly mounted on the carriage assembly for receiving and inserting a dowel into the dowel bore when the carriage assembly is in the second position.

9. The pocket screw and dowel apparatus according to claim 1, wherein the apparatus further comprises a pneumatic indexing valve configured to control configured to control pneumatic actuators in predetermined sequences.

10. The pocket screw and dowel apparatus according to claim 1, wherein the body assembly further comprises: a first sheet material having an assembly slot having a slot width and slot length, and a fastener hole having a radius R, wherein a slot area of the assembly slot overlaps with a hole area of the fastener hole such that a radius of the hole extends into the slot area of the assembly slot; a second sheet material including an assembly tab having a tab width and a tab length substantially equal to the slot width and slot length respectively, the assembly tab being inserted into the assembly slot, assembly tab has a tab surface facing the fastener hole; and a threaded fastener having external threads, the threaded fastener treaded into the fastener hole engaging with and deforming the tab surface to mechanically secure the threaded fastener to the assembly tab, and in turn secure the first sheet material to the second sheet material.

11. The pocket screw and dowel apparatus according to claim 10, wherein the first sheet material includes at least three assembly slots spaced along a first curve, and wherein the second sheet material includes at least three assembly tabs, wherein the second sheet material bowed along a second curve that is complementary in shape the first curve creating a non-linear abutting interface between the first sheet material and the second sheet material.

12. The pocket screw and dowel apparatus according to claim 1, further comprising: a ratcheting indexer rotatable about a valve axis A and having a plurality of indexed settings, the indexer including an inlet located on a radius R from the valve axis, the inlet allowing pressured air to flow through the indexer;an upper plate including a plurality of apertures radially spaced about the valve axis A and along the radius R, each of the plurality of apertures corresponding to a respective setting of the plurality of indexed settings; a valve plate including a plurality of passageways, each having a first end and a second end, each first end radially spaced about the valve axis A and along the radius R, each first end corresponding to a respective one of the plurality of apertures, and each second end being spaced from any adjacent second ends; and a lower plate including a plurality of outlets, each aligned with a respective second end and in fluid communication with a respective one of the plurality of passageways; wherein the inlet is fluidly connected to a respective one of the plurality of outlets depending upon which indexed setting the indexer is positioned; and wherein the indexer, the upper plate, the valve plate, and the lower plate are all formed of planer sheet materials, and wherein the indexer abuts against the upper plate, the upper plate abuts against the valve plate, and the valve plate abuts against the lower plate.

13. A body assembly structurally supporting components of an apparatus, the body assembly comprising: a first sheet material having an assembly slot having a slot width and slot length, and a fastener hole having a radius R, wherein a slot area of the assembly slot overlaps with a hole area of the fastener hole such that a radius of the hole extends into the slot area of the assembly slot; a second sheet material including an assembly tab having a tab width and a tab length substantially equal to the slot width and slot length respectively, the assembly tab being inserted into the assembly slot, assembly tab has a tab surface facing the fastener hole; and a threaded fastener having external threads, the threaded fastener treaded into the fastener hole engaging with and deforming the tab surface to mechanically secure the threaded fastener to the assembly tab, and in turn secure the first sheet material to the second sheet material.

14. The body assembly according to claim 13, wherein the first sheet material includes at least three assembly slots spaced along a first curve, and wherein the second sheet material includes at least three assembly tabs, wherein the second sheet material bowed along a second curve that is complementary in shape the first curve creating a non-linear abutting interface between the first sheet material and the second sheet material.

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