Lug Loader Skew Correction via Independent Conveyor Pairs
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Solution Overview
Problem
Conventional lug loaders are inadequate at higher feed speeds and struggle to effectively singulate and allocate lumber of varying widths, thickness, and orientations, particularly in curve sawing mills where lumber is bowed, cupped, or skewed.
Innovation Solution
A system utilizing independently actuable pairs of endless conveyors to orient and space lumber transversely across a lugged conveyor, allowing for skew correction and consistent spacing, which simplifies loading by eliminating the need for mechanical lug loaders and reduces maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional lug loaders are used, then lumber can be loaded onto the conveyor, but they become inadequate at higher feed speeds and cannot effectively handle varying widths, thickness, and orientations
Solution Approach 1:
The system divides the lumber handling function into multiple independently actuable conveyor pairs, each capable of independent speed control. This segmentation allows each conveyor pair to handle specific orientation corrections independently, enabling the system to process varying widths, thicknesses, and orientations at higher speeds without compromising loading effectiveness.
Solution Approach 2:
The system employs dynamically adjustable conveyor speeds for each pair of conveyors. By independently controlling the speed of each conveyor pair, the system can adapt to real-time variations in lumber characteristics (width, thickness, orientation) and maintain reliable loading performance across a range of feed speeds, resolving the contradiction between speed and effectiveness.
2Ease of operation
If mechanical lug loaders are used to singulate and allocate lumber, then lumber can be positioned on the conveyor, but the device complexity increases and maintenance requirements increase
Solution Approach 1:
The system replaces complex mechanical singulation and allocation mechanisms with a simplified conveyor-based approach. By using independently actuable conveyors with controllable speeds, the system achieves singulation and allocation through differential speed control rather than complex mechanical interventions, reducing device complexity and maintenance requirements while maintaining operational capability.
Solution Approach 2:
The conveyor pairs serve multiple functions simultaneously: they convey lumber downstream, correct skew, and perform singulation and allocation. This multi-functionality eliminates the need for separate dedicated mechanisms for each task, simplifying the overall system while maintaining comprehensive lumber handling capability.
3Reliability
If conventional lug loaders are used to handle bowed, cupped, or skewed lumber, then lumber can be transported, but the ability to maintain consistent spacing and correct skew is limited
Solution Approach 1:
The system uses dynamically controllable conveyor speeds to correct skew and maintain consistent spacing. By independently adjusting the speed of each conveyor pair, the system can actively compensate for bowed, cupped, or skewed lumber at higher handling speeds, achieving both reliable skew correction and improved productivity compared to conventional fixed-speed systems.
Solution Approach 2:
The system incorporates sensors that detect lumber position and orientation, providing feedback to the control system. This feedback enables real-time adjustment of conveyor speeds to correct skew and maintain consistent spacing, allowing the system to handle problematic lumber (bowed, cupped, skewed) effectively at higher speeds by continuously adapting to actual lumber conditions.
Data Source
AI summary
Embodiments provide methods, systems, and apparatuses for loading workpieces in a flow direction into the spaced apart lugs on a lugged conveyor with the workpieces oriented transverse to the flow direction. The lug loader includes an array of pairs of endless conveyors configured to convey workpieces toward a lugged conveyor. The first and second endless conveyors of each pair are spaced laterally apart across the flow direction and aligned substantially in the flow direction. The array can form a continuous or discontinuous transport surface. Some pairs of endless conveyors in the array may overlap one or more other pairs of endless conveyors in the array. At least one pair of endless conveyors in the array may include two or more endless conveyors that are independently driven at different speeds and/or in different directions to de-skew a workpiece.