Automated Board And Panel Scorching for Consistent Flamed Finishes
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Solution Overview
Problem
Conventional manual scorching processes for producing flamed wood aesthetics on boards and panels are inefficient, inconsistent, unsafe, and limited to small, solid-wood materials, with a high risk of over-burning and difficulty in achieving consistent appearances.
Innovation Solution
A conveyor-based system with automated scorching assemblies, including burners and a central controller, allows for controlled scorching of various wood materials, enabling consistent and efficient production of desired aesthetic appearances through programmable scorching profiles and safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual scorching process is used, then flexibility in handling different materials is maintained, but productivity is low and consistency is poor
Solution Approach 1:
The patent replaces manual mechanical operation with an automated system where a conveyor belt transports panels through a controlled scorching zone. Burners are mounted on the conveyor and can be selectively activated to scorch specific areas of the panel surface, eliminating the need for manual hand-manipulation of burners while maintaining precise control over the scorching process.
Solution Approach 2:
The system allows dynamic adjustment of scorching parameters including burner activation patterns, conveyor speed, and burner positioning. The controller can vary these parameters to handle different panel sizes, materials, and desired aesthetic effects, enabling the same automated system to adapt to multiple production scenarios without sacrificing consistency.
2Manufacturing precision
If manual scorching process is used, then operator flexibility is maintained, but manufacturing precision and consistency are poor
Solution Approach 1:
The patent replaces manual burner manipulation with an automated conveyor system where burners are mounted on the conveyor and can be selectively activated. This substitution eliminates human variability in applying pressure, angle, and duration, ensuring consistent scorching results across all panels while simplifying the operational process.
Solution Approach 2:
The system incorporates a controller that receives input about the desired scorching profile and automatically adjusts burner activation patterns accordingly. This feedback mechanism ensures that the scorching process achieves the target aesthetic appearance with precision, while the automated control makes the operation simpler despite the increased system complexity.
3Reliability
If manual scorching process is used, then adaptability to material types is maintained, but risk of over-burning is high
Solution Approach 1:
The system allows dynamic adjustment of scorching parameters including burner activation patterns, conveyor speed, and burner positioning. The controller can vary these parameters in real-time based on panel type, thickness, and material properties, enabling precise control that prevents over-burning while maintaining high production speed through automated processing.
Solution Approach 2:
The burners can be activated in periodic or sequential patterns as panels move through the scorching zone. This periodic activation allows the system to apply heat in controlled intervals, ensuring thorough scorching of the desired areas while preventing overheating or burning through, especially important when processing engineered woods that are more susceptible to damage.
4Object-affected harmful factors
If manual scorching process is used, then safety control is maintained by operator judgment, but safety risks are high
Solution Approach 1:
The patent replaces manual burner handling with an automated conveyor system where burners are mounted on the conveyor and can be selectively activated. This substitution eliminates the safety risks associated with manual flame handling, as the automated system provides consistent control over burner activation and positioning without requiring operator proximity to open flames.
Solution Approach 2:
The system incorporates safety feedback mechanisms where the controller monitors burner activation and can automatically adjust or shut off burners based on detected conditions. This feedback system provides an additional layer of safety by preventing unsafe conditions before they occur, while the automated operation eliminates the need for operator judgment in safety-critical situations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables mass production of boards and panels with consistent flamed looks, reducing human error, increasing productivity, and ensuring safety, while accommodating different materials and sizes, including engineered woods.
Implementation Method 1
Each burner can be mounted to the combustion chamber and at least partially received within the combustion chamber. Each burner can be oriented toward the conveyor.
Data Source
AI summary
A system having a conveyor assembly, at least one scorching assembly, and a central controller. The conveyor assembly has a conveyor that effects movement of at least one board or panel relative to a movement axis. Each scorching assembly has a combustion chamber, at least one burner, and at least one processing unit. Each burner can be mounted to the combustion chamber and at least partially received within the combustion chamber. Each burner can be oriented toward the conveyor. The at least one processing unit can be communicatively coupled to the at least one burner and configured to selectively control activation and operation of the at least one burner. The central controller can be communicatively coupled to each processing unit of the at least one scorching assembly and configured to receive a user input corresponding to a scorching profile for the at least one board or panel.