Lumber Crown Orientation via Laser Scanning and Dynamic Trolley Control
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Solution Overview
Problem
Current lumber handling systems face inefficiencies in automatically calibrating and managing lumber stations, detecting board curvature, and optimizing trolley speed based on board size and weight, leading to reduced productivity and safety concerns.
Innovation Solution
The system employs a laser scanner and trolley with independent motors to automatically calibrate lumber stations, detect board curvature, and adjust trolley speed based on board size and weight, using multiple picking heads and board flippers to orient boards correctly for sawing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection and delivery of boards is used, then workers can visually inspect boards for warpage and orient crowns favorably, but productivity is reduced and safety concerns arise
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical scanning system using lasers and sensors to detect board curvature and crown orientation. This substitution maintains inspection quality while eliminating the productivity limitations of manual handling.
Solution Approach 2:
The system enables boards to be automatically oriented and positioned based on detected crown characteristics without human intervention. The automated system serves itself by detecting, analyzing, and adjusting board orientation to achieve favorable crown positioning for structural assembly.
2Productivity
If automated lumber handling systems are used, then productivity increases, but the system lacks ability to detect board curvature and optimize crown orientation
Solution Approach 1:
The patent implements a feedback loop where optical sensors continuously detect board crown characteristics, and this information feeds back to the control system to automatically adjust board orientation. This closed-loop control ensures favorable crown positioning is achieved while maintaining high productivity.
Solution Approach 2:
The system performs preliminary detection and orientation adjustment of boards before they enter the processing workflow. By pre-positioning boards with favorable crown orientation, the system ensures quality outcomes are achieved upstream in the process rather than requiring post-processing adjustments.
3Productivity
If fixed trolley speed is used, then system operation is simple, but productivity is reduced due to inability to optimize for board size and weight
Solution Approach 1:
The patent transitions from fixed trolley speed to dynamic speed adjustment based on real-time detection of board characteristics. The trolley system automatically adapts its speed profile to match board weight and size, optimizing delivery efficiency while managing complexity through automated control algorithms.
4Productivity
If rapid calibration of lumber stations is required, then productivity improves, but system complexity increases
Solution Approach 1:
The patent replaces manual calibration procedures with automated optical scanning and sensor-based measurement systems. This substitution enables rapid station calibration by using light-based measurement instead of physical measurement tools and manual adjustment, significantly reducing setup time while managing complexity through software automation.
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
This solution enables rapid and accurate calibration of lumber stations, efficient board handling, and improved safety by optimizing trolley speed and board orientation, enhancing productivity and reducing manual intervention.
Implementation Method 1
a laser scanner and trolley with independent motors to automatically calibrate lumber stations, detect board curvature
Data Source
AI summary
A lumber handling method identifies the existence and direction of crowning in dimensional lumber and automatically orients the board and specifies a cutting direction prior to a saw cutting the board into one or more board segments to be used in a structural board assembly, such as in a truss or a wall panel. Crowning is a curve that occurs along a narrow convex edge of a board, wherein the curve is about an axis that is perpendicular to the board's widest face. In some examples, a board's crown is detected by a row of photoelectric sensors. In some examples, the method involves calibrating the sensors by passing a straight board past the sensors. In some examples, the convex and/or concave edges of the board are marked.