Lumber Grade Annunciation via Optical Projection
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Solution Overview
Problem
Automated lumber grading systems often require quality control checks and leave visible marks on lumber, which can be inaccurate and unsightly, especially when traditional paint-based methods are used.
Innovation Solution
A system utilizing projectors to directly project lumber grade information and other data onto boards as they pass through a processing unit, allowing for accurate and customizable display of grades, defects, and other information without physical marking, using an ID reader and camera system to track and adjust projections accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional paint-based marking methods are used to display lumber grades, then grade information can be displayed on lumber, but the lumber surface becomes marked and unsightly
Solution Approach 1:
The patent replaces the mechanical paint spraying system with an optical projection system. Projectors mounted above the conveyor belt project grade information, defect locations, and other data directly onto the lumber surface without physical contact. This substitution eliminates the harmful effect of paint marks while maintaining the information display function.
Solution Approach 2:
Instead of physically marking the lumber with paint, the system creates optical copies of grade information and defect locations by projecting images onto the lumber surface. These projected images serve as temporary visual copies that can be seen during processing but do not permanently alter the lumber appearance.
2Measurement precision
If automated grading systems use image scanning and processing to identify lumber characteristics, then grading accuracy is improved, but the system becomes complex and requires quality control checks
Solution Approach 1:
The system incorporates feedback mechanisms where the projection system receives real-time data from the imaging and grading systems, then immediately projects the processed information onto the corresponding lumber pieces. This closed-loop feedback reduces the need for separate quality control checks by ensuring accurate, real-time information display.
Solution Approach 2:
The projection system serves multiple functions: displaying grade information, marking defect locations, indicating cut positions, and providing visual feedback for quality control. This multi-functionality consolidates several separate systems into one, reducing overall system complexity while maintaining high grading accuracy.
3Productivity
If lumber is transported on lugged or unlugged chains through a mill, then continuous processing is enabled, but tracking and marking individual boards becomes difficult
Solution Approach 1:
The imaging system continuously captures images of lumber pieces as they move along the conveyor, automatically tracking each piece without requiring manual intervention or additional tracking hardware. The system uses the natural movement and positioning of lumber on the conveyor to facilitate automatic identification and tracking.
Solution Approach 2:
The patent replaces mechanical tracking and marking systems with an optical imaging and projection system. Cameras and image processing algorithms track individual boards through the processing line, while projectors mark them with grade information. This substitution enables accurate tracking and marking of individual boards during continuous processing without the complexity of mechanical tracking systems.
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
Provides a precise and clean method for displaying lumber grades and defects, reducing the need for quality control checks and maintaining the appearance of freshly planed lumber, while allowing for accurate trim decisions and multi-grade cut-in-two displays on various surfaces.
Implementation Method 1
A system utilizing projectors to directly project lumber grade information and other data onto boards
Data Source
AI summary
Embodiments provide grade annunciator systems that allow a lumber workpiece traveling in a workflow path to be labeled with a projected image that conveys information about the grade, a cut line, and/or the location of a defect in the workpiece. In some embodiments, the system includes a conveyor configured to convey lumber workpieces in a workflow path, and a projector or series of projectors configured to project an image or symbol onto a surface of the workpiece, wherein the image or symbol indicates grade, a cut line, and/or the location of a defect in the workpiece. Other embodiments are methods of labeling a lumber workpiece in a workflow path, the methods includes conveying the lumber workpiece along the workflow path, and projecting an image or symbol onto a surface of the workpiece as it is conveyed along the workflow path.