Method for producing flush panel core material

Abstract

Provided is a method for producing a flush panel core material wherein the following steps are performed: a picking step for imaging, with a 3D camera 21, a plurality of pieces of rectangular lumber 10 of differing lengths which are mixed together in a container 20, then performing image processing on the captured image to recognize the rectangular lumber 10, and extracting the rectangular lumber 10 with a picking device 23; a joining step for joining ends of the extracted pieces of the rectangular lumber 10 to form a continuous long base core material 11; and a cutting step for cutting the base core material 11 to a prescribed length to obtain a core material 12. Thus, joined parts are formed in which the ends of pieces of rectangular lumber 10 are joined together.

Description

Method for Producing Core Material for Flash Panel

[0001] The present disclosure relates to a method for producing a core material for a flash panel.

[0002] Conventionally, a method for producing a core material for a flash panel has been proposed, in which a plurality of wooden square members such as offcuts are bonded to form an elongated raw core material, and the raw core material is cut into an appropriate length to produce the core material for a flash panel (see Patent Document 1).

[0003] Japanese Patent No. 7386430

[0004] Incidentally, in order to form the raw core material, the target wooden square members must first be identified before bonding, and it is expected that time will be consumed if such preparation is performed manually. For example, when wooden square members with various cross-sectional dimensions and shapes are mixed in a container, it naturally takes time to visually take out the desired type of wooden square members from the container.

[0005] The present invention has been proposed in consideration of such circumstances, and an object thereof is to provide a method for producing a core material for a flash panel, which can efficiently form a core material for a flash panel based on a plurality of wooden square members such as offcuts.

[0006] In order to achieve the above object, the method for producing a core material for a flash panel according to the present disclosure is a method for producing a core material used for a flash panel, comprising: a picking step in which a plurality of wooden square members with different lengths are mixed and loaded in a container, after the wooden square members in the container are imaged by a three-dimensional camera, the captured image is subjected to image processing to identify the wooden square members, and the wooden square members are taken out by a picking device; a joining step of bonding ends of the taken-out wooden square members to each other to form a series of elongated raw core material; and a cutting step of cutting the raw core material into a predetermined length dimension to obtain the core material, wherein a joint between the ends of the wooden square members is formed by carrying out the above steps.

[0007] Since the method for producing a core material for a flash panel according to the present invention adopts the aforementioned procedure, formation of a core material for a flash panel based on a plurality of wooden square members such as offcuts can be efficiently implemented.

[0008] This figure shows a schematic flow of a method for manufacturing a core material for a flash panel according to the present disclosure. This is a front view of a core assembly of an example of a flash panel manufactured by the same manufacturing method.

[0009] The following describes an embodiment of the method for manufacturing a core material for a flash panel according to this disclosure, based on the attached drawings. First, the basic procedure for the method for manufacturing a core material for a flash panel according to the embodiment will be described.

[0010] The method for manufacturing the core material for the flash panel according to the embodiment (hereinafter referred to as "this manufacturing method") is as follows:

[0011] The container 20 used in this manufacturing method contains a mixture of wooden square timbers 10 of different lengths, and the following steps are performed sequentially on the premise that the wooden square timbers 10 in this container 20 will be used.

[0012] Picking process: After capturing images of the wooden timbers 10 inside the container 20 with a 3D camera 21, the captured images are processed to identify the wooden timbers 10 and they are picked up by a picking device 23. Joining process: The ends of the picked wooden timbers 10 are joined together to form a series of long, basic core materials 11. Cutting process: The basic core materials 11 are cut to a predetermined length to obtain core materials 12.

[0013] Next, the detailed steps of this manufacturing method will be explained with reference to the schematic flowchart in Figure 1.

[0014] As a preparatory step for this manufacturing method, wooden square timbers 10, such as scraps remaining in the cross-cutting device (not shown) and scraps generated due to other factors, are collected in a predetermined container 20. Note that the wooden square timbers 10 stored in the container 20 may include not only scraps, but any type of wooden square timber 10 that can fit inside the container 20.

[0015] This manufacturing method involves taking out a desired wooden square timber 10 from a container 20 containing various wooden square timbers 10, and using the removed wooden square timber 10 to obtain a core material 12 for a flush panel.

[0016] In this example, a container 20 contains multiple types of wooden square timbers 10, such as six different types, and the procedure for selecting a desired wooden square timber 10 from among them to form a core material 12 is shown. Here, the desired wooden square timber 10 refers to attributes of the wooden square timber 10, such as cross-sectional dimensions and shape.

[0017] (1) Picking process (1-1) Imaging sub-process (A-1 in Figure 1) First, the wooden square timber 10 inside the container 20 is imaged with a 3D camera 21 so as to include the end grain (cross section 10a at the end) or so as to be able to identify the cross-sectional dimensions and shape (hereinafter referred to as cross-sectional information). The cross-sectional shape among the cross-sectional dimensions and shape includes elements that can identify the type of material, such as laminated veneer timber or particleboard (for example, the pattern that appears on the cross section 10a).

[0018] The 3D camera 21 shown in Figure 1 is preferably a 3D vision camera, and it is desirable that it not only acquires 3D data but also performs image processing, including the detection of the position of an object. In Figure 1, an image processing device 22 that performs image processing is shown separately, but this image processing device 22 may also be included in the 3D camera 21.

[0019] As shown in Figure 1, the 3D camera 21 is equipped with four cameras 21a and one projector 21b. The projector 21b is a device that illuminates an object with light so that the cameras 21a can capture the object.

[0020] The 3D camera 21 may be capable of capturing images from various directions. For example, the 3D camera 21 may be movable to enable capturing images from various directions. The 3D camera 21 may be made movable using a drone or similar device.

[0021] Next, the image processing device 22, which is built into or connected to the 3D camera 21, processes the captured image. The cross-sectional information of the wooden beam 10 obtained through this image processing is identified to determine whether or not it is the desired wooden beam 10.

[0022] The cross-sectional information setting data for identifying the desired wooden timber 10 can be pre-set in the 3D camera 21 or image processing device 22. The desired wooden timber 10 can be identified by whether or not the cross-sectional information obtained through image processing matches the pre-set cross-sectional information setting data.

[0023] (1-2) Removal sub-process (A-2 in Figure 1) If the cross-sectional information obtained by image processing is determined to be that of the desired wooden timber 10, the wooden timber 10 is removed by the picking device 23 and transferred to and placed on the workbench 24 for the next process.

[0024] Furthermore, the positional information data of the desired wooden timber 10 within the container 20, which has been identified and determined by the image processing device 22, can be generated by the image processing device 22 and transmitted to the picking device 23, or shared between the image processing device 22 and the picking device 23.

[0025] The workbench 24 may be a work conveyor. In order to efficiently transfer the wooden timbers 10 to the transport conveyor 26 used in the next process, it is desirable that they be placed on the workbench 24 facing the same direction, as shown in Figure 1. In the example in Figure 1, the wooden timbers 10 are arranged in the short direction on the workbench 24.

[0026] In the picking process (A-1, A-2 in Figure 1), multiple wooden timbers 10 may be repeatedly removed in a single imaging sub-process. Of course, assuming that the position of the wooden timbers 10 inside the container 20 will change after removal, one imaging sub-process and one removal process may be treated as one set of picking processes, and this can be repeated.

[0027] Furthermore, the 3D camera 21, image processing device 22, and picking device 23 may be systematized (robotized) so that the imaging sub-process and the retrieval sub-process are executed asynchronously. For example, the imaging sub-process may repeat imaging at a fixed period, and in the retrieval sub-process, the desired wooden timber 10 may be identified based on the most recently captured image at the timing when the picking device 23 starts picking the wooden timber 10.

[0028] The picking process may involve repeatedly performing a series of operations: picking up one wooden beam 10 using a picking device 23, imaging the picked-up wooden beam 10, and identifying the wooden beam 10 through image processing. The imaging of the picked-up wooden beam 10 can be performed while the wooden beam 10 is suspended by the picking device 23.

[0029] In this series of processes, when identifying the cross-sectional information, if it is determined to be the desired wooden timber 10, it should be moved to the workbench 24, and if it is determined not to be the desired wooden timber 10, it should be moved to another container (not shown). In short, it may also be a method in which the desired wooden timber 10 is identified and retrieved by repeatedly performing pickup for image processing (for example, holding in a suspended state), imaging of the wooden timber 10, and identification by image processing.

[0030] This method can be used when using a 3D camera 21 with low accuracy, or when it is desired to obtain cross-sectional information more reliably and accurately. Wooden timbers 10 that are determined not to be the target are moved to another container (not shown) and excluded, making it easier for humans to monitor.

[0031] (2) Joining process (2-1) Adhesive application sub-process (B-1 in Figure 1) On the workbench 24, adhesive applicators 25 such as glue spreaders are arranged in a row corresponding to the arranged wooden square timbers 10, and adhesive is applied to both cross-sections 10a of the wooden square timbers 10 simultaneously or sequentially from the downstream side. Various types of adhesives can be used, such as water-based emulsion adhesives such as polyvinyl acetate-based and modified vinyl acetate-based adhesives.

[0032] The wooden lumbers 10 to which adhesive has been applied are transported by a work conveyor onto a transport conveyor 26 for joining the wooden lumbers 10 together and cutting the core material 11 to a predetermined length. In particular, if the workbench 24 is a work conveyor, the wooden lumbers 10 should be transported to the transport conveyor 26 in order from the downstream side of the workbench 24.

[0033] (2-2) Joining sub-process (B-2 in Figure 1) A joining device 27 is provided on the upstream side of the conveyor belt 26. This joining device 27 is a device that press-joins the end grain (cross-section 10a) of the wooden square timbers 10 together. A high-frequency dielectric heating press device may also be used.

[0034] The wooden square timber 10, which has been transported from the adhesive application sub-process, is joined to the tail end cross section 10a of the downstream wooden square timber 10 by the joining device 27. The downstream wooden square timber 10 is then joined to the further downstream wooden square timber 10 to form a single, elongated core material 11. In other words, the newly transported wooden square timber 10 is joined to the tail end of the core material 11 at that point. In short, as joining is repeated, the core material 11, including the joint 15, extends toward the tail end.

[0035] Furthermore, the wooden square timbers 10 may be joined together using dowels, in which case it goes without saying that dowel holes must be drilled before applying adhesive, and the dowels must be attached to one end of one of the pieces after applying adhesive.

[0036] (3) Cutting process (C in Figure 1) This process involves cutting the raw core material 11 to the desired length of core material 12 on the conveyor belt 26. The cutting device 28 is located downstream of the joining device 27 on the conveyor belt 26. In this process, it is necessary to cut the material to a dimension that matches the desired length of core material 12. The cutting dimension can be set, for example, in the cutting device 28.

[0037] In this embodiment, a stopper 29 is provided to set the position of the leading edge 11a of the core material 11 that has flowed on the conveyor belt 26 as the zero position, so that the cutting device 28 can cut at a predetermined position.

[0038] A servo motor (not shown) equipped with a stopper 29 moves to adjust to a predetermined dimension, and a cutting blade (not shown) installed in a fixed position cuts the core material 12 to a dimension that matches the desired length. In this way, the desired core material 12 is obtained.

[0039] The cut core material 12 is transported to a predetermined location. The core material 12 formed in this way may include those in which one or more joints 15 are formed in the middle of the longitudinal direction, as shown in the illustrated example.

[0040] The cutting device 28 may be equipped with a position adjuster (not shown) consisting of a servo motor, rack and pinion, etc. In this case, the cutting device 28 moves the cutting blade (not shown) upstream from the zero position by the desired length, and cuts the raw core material 11 at that position to obtain the desired core material 12.

[0041] As described above, the cutting process is carried out on a common conveyor belt 26 for both the cutting process and the joining sub-process. The cutting process and the joining process (joining sub-process) should be performed in coordination between the cutting device 28 and the joining device 27.

[0042] Since the joining sub-process and the cutting process operate independently, the length of the core material 11 on the conveyor belt 26 fluctuates. However, if the cutting device 28 and the joining device 27 are coordinated, the speed of each process can be adjusted, preventing the core material 11 on the conveyor belt 26 from becoming excessively long or short.

[0043] According to the manufacturing method described above, a desired type of wooden timber 10 can be quickly identified from among multiple types of wooden timber 10 collected in the container 20, and that wooden timber 10 can be transferred to the next process. As a result, the entire process up to the formation of the core material 12 made of wooden timber 10 can be carried out efficiently. As shown in the figure example, even if various types of wooden timber 10 are mixed in the container 20, the picking process can be expedited without human intervention.

[0044] Furthermore, this manufacturing method can be used not only when wooden square timbers 10 with different cross-sectional information are collected in the container 20, but also when wooden square timbers 10 of the same type are collected. Since this manufacturing method can distinguish wooden square timbers 10 of the same type based on their cross-sectional information, even when the method is implemented on the premise that wooden square timbers 10 of the same type are collected in the container 20, if, for example, other types of wooden square timbers are mixed in with the container 20, they can be excluded from the identification target.

[0045] The flash panel core material 12 obtained by the present production method can be used as the core material 12 for various doors such as sliding doors, top-hung doors, and swing doors. Fig. 2 is a front view of the core structure of a sliding door. The core material 12 obtained by the present production method is used for vertical core members 12a and horizontal core members 12b, and is also used for block members 12c, that is, reinforcing materials (binding members) for handle portions and door roller portions.

[0046] In the above embodiment, a picking condition is that the cross-section information (cross-sectional dimension and shape) is the same, but the length of the wooden square members 10 may be further identified, and the condition that the length falls within a predetermined range may be added to the picking conditions. For example, wooden square members 10 that are too short or too long to make adhesive application and joining difficult may be excluded from picking targets.

[0047] Furthermore, when the core material 12 may be formed with mixed types of materials such as laminated veneer lumber and particle board, picking may be performed without discriminating elements that can identify the product type.

[0048] <Supplementary Note> According to the description of the above embodiment, the following technology is disclosed.

[0049] <Technology 1> A method for producing a core material used for a flash panel, wherein a plurality of wooden square members having different lengths are mixedly loaded in a container, and the method comprises: a picking step of imaging the wooden square members in the container with a three-dimensional camera, then performing image processing on the captured images to identify the wooden square members, and taking out the wooden square members with a picking device; a joining step of joining ends of the taken-out wooden square members to each other to form a series of elongated raw core material; and a cutting step of cutting the raw core material to a predetermined length dimension to obtain the core material, wherein a joint between the ends of the wooden square members is formed by carrying out the above steps. A method for producing a core material for a flash panel, characterized in that.

[0050] <Technology 2> The method for producing a core material for a flash panel according to Technology 1, wherein a plurality of types of said wooden square members having different cross-sectional dimensions and shapes are mixed in said container, and after imaging with said three-dimensional camera, said wooden square members are identified by image processing of the captured images, and said wooden square members having the same cross-sectional dimension and shape are taken out by said picking device.

[0051] <Technology 3> The picking device places the picked-up wooden timbers on a workbench so that they are all facing the same direction, a method for manufacturing core material for a flush panel as described in Technology 1 or Technology 2.

[0052] 10 Wooden square timber 10a Cross-section 11 Raw core material 12 Core material (core material for flash panel) 12a Vertical core material 12b Horizontal core material 12c Segment material 15 Joint 20 Container 21 3D camera 22 Image processing device 23 Picking device 24 Workbench 25 Adhesive applicator 26 Conveyor belt 27 Joining device 28 Cutting device 29 Stopper

Claims

1. A method for manufacturing a core material used in a flash panel, characterized in that a plurality of wooden square timbers of different lengths are mixed in a container, a picking step is performed in which the wooden square timbers in the container are imaged with a three-dimensional camera, the imaged images are processed to identify the wooden square timbers and they are picked up with a picking device, a joining step is performed in which the ends of the picked-up wooden square timbers are joined together to form a series of long, basic core materials, and a cutting step is performed in which the basic core materials are cut to a predetermined length to obtain the core material, thereby forming the joints between the ends of the wooden square timbers.

2. The method for manufacturing a core material for a flash panel, wherein, according to claim 1, a plurality of types of wooden square timbers having different cross-sectional dimensions and shapes are mixed in the container, and after imaging with the three-dimensional camera, the wooden square timbers are identified by image processing of the captured image, and the wooden square timbers having the same cross-sectional dimensions and shape are picked up with the picking device.

3. The method for manufacturing a core material for a flush panel, wherein the picking device places the picked-up wooden timbers on a workbench so that they are all facing the same direction.

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