Lumber Retrieval Calibration Using Laser Scanning and Track Error Compensation
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Solution Overview
Problem
Existing lumber handling systems face challenges in efficiently reconfiguring lumber stations, calculating board quantities, and ensuring safety during high-speed operations, particularly due to manual calibration processes and limitations in handling boards of varying sizes and orientations.
Innovation Solution
The system employs a combination of laser scanning for automatic station calibration, trolley speed adjustment based on board weight and length, and dual independent picking heads to handle multiple boards simultaneously, while also detecting crown orientation and using a shuttle trolley for optimized delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual calibration processes are used for lumber station configuration, then system complexity is reduced, but reconfiguration time and productivity are increased
Solution Approach 1:
The system automatically detects lumber board ends using optical sensors and self-calibrates station positions without manual intervention. The controller processes sensor signals to identify board locations and adjusts station configurations autonomously, eliminating the need for operators to manually calibrate each station while significantly reducing reconfiguration time.
Solution Approach 2:
Manual mechanical calibration processes are replaced with an automated optical detection system. Optical sensors scan for lumber board ends, and the controller uses this data to automatically determine station positions and configurations, substituting human-operated mechanical adjustment with automated optical-mechanical integration.
2Productivity
If high-speed trolley operations are used for lumber delivery, then productivity is improved, but safety risks and potential damage increase
Solution Approach 1:
The trolley system dynamically adjusts its operating speed based on real-time conditions. The controller monitors board characteristics, station positions, and operational parameters to optimize trolley speed, allowing high-speed operation during stable conditions while automatically reducing speed when safety concerns arise, thus balancing productivity and safety.
Solution Approach 2:
The system incorporates feedback mechanisms where sensors continuously monitor board positions, trolley location, and operational status. This feedback is processed by the controller to make real-time adjustments to trolley speed and positioning, ensuring safe operation at high speeds by automatically responding to changing conditions.
3Device complexity
If single picking head systems are used, then device complexity is reduced, but handling capacity for multiple board sizes is limited
Solution Approach 1:
The picking system is segmented into multiple independent picking heads that can operate simultaneously or independently. Each picking head is equipped with its own board detection and gripping mechanisms, allowing the system to handle multiple boards of different sizes and orientations at the same time, significantly increasing handling capacity while maintaining manageable complexity through modular design.
Solution Approach 2:
Each picking head is designed as a universal module capable of handling various board sizes, thicknesses, and orientations. The picking heads can be configured to work together or independently, providing multi-functionality that allows the system to adapt to different lumber types and delivery requirements without requiring completely different picking mechanisms.
4Measurement precision
If automatic laser scanning calibration is implemented, then measurement precision is improved, but device complexity and initial cost increase
Solution Approach 1:
Traditional manual measurement and calibration tools are replaced with automatic laser scanning systems. The laser scanner precisely detects board ends and station positions optically, providing high measurement precision without requiring manual measurement devices. The controller automatically processes the laser scanning data to complete calibration, replacing complex manual measurement procedures with automated optical detection.
Solution Approach 2:
The laser scanning calibration system operates autonomously without requiring external measurement tools or manual intervention. The system self-calibrates by detecting board positions through laser scanning and automatically adjusting station configurations based on the detected data, eliminating the need for separate calibration equipment and reducing operational complexity despite the advanced technology used.
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 approach enables rapid and accurate reconfiguration of lumber stations, improved safety through variable trolley speeds, and increased productivity by handling multiple board sizes and orientations efficiently, enhancing overall lumber delivery and processing efficiency.
Implementation Method 1
a trolley apparatus carrying a laser scanner over the plurality of stations
Implementation Method 2
laser scanning for automatic station calibration
Data Source
AI summary
A lumber retrieval method renders a lumber handling system readily adaptable to compensate for irregular floors, an irregular overhead track, and variable station locations. In some examples, the method involves determining a plurality of floor-to-track error values that vary based on the floor and the track deviating from being parallel to each other, recording the plurality of floor-to-track error values on a controller, and calculating a plurality of error-compensated reading via the controller based on the plurality of lumber scanned reading and the plurality of floor-to-track error values.