Moulder Laser Projection for Wood Workpiece Dimension Verification
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Solution Overview
Problem
Molding machines often produce workpiece rejects due to incorrectly set machine elements, leading to inefficient processing and waste, especially when handling raw wood with varying dimensions and profiles.
Innovation Solution
The integration of lasers within the molding machine to project straight lines onto the workpiece, indicating the expected chip removal dimensions and geometry, allowing operators to verify correct machine settings before processing, thereby minimizing rejects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machine elements are set based on experience or trial-and-error, then the machine can be operated with simple equipment, but workpiece rejects increase due to incorrect settings
Solution Approach 1:
The laser projection system displays the expected chip removal and final workpiece dimensions on the workpiece itself before machining begins. This preliminary visualization allows operators to verify machine element settings (dressing table height, jointing ruler position, spindle positions) and make corrections before actual machining, preventing workpiece rejects due to incorrect settings.
Solution Approach 2:
The laser projection acts as an intermediary between the machine element settings and the actual workpiece machining. It provides a visual representation of the machining outcome based on current settings, serving as a mediator that allows operators to verify and adjust settings without actually removing material from the workpiece.
2Adaptability or versatility
If machine elements are frequently adjusted for different workpiece profiles, then the machine can handle various workpiece types, but the risk of incorrect settings and rejects increases
Solution Approach 1:
Before machining each workpiece profile, the laser projection system visualizes the expected chip removal and final dimensions based on the current machine element settings. This allows operators to verify settings for each specific workpiece profile before machining begins, ensuring accuracy even when frequently adjusting for different workpiece types.
Solution Approach 2:
The laser projection provides immediate visual feedback to operators about the relationship between machine element settings and the expected machining outcome. When operators adjust the dressing table height, jointing ruler position, or spindle positions for different workpiece profiles, the laser projection instantly reflects these changes, allowing for real-time verification and correction.
3Device complexity
If machine settings are verified after workpieces pass through the machine, then the machine structure remains simple, but workpiece rejects occur due to undetected setting errors
Solution Approach 1:
The laser projection system serves as a simple intermediary device that provides setting verification without requiring complex structural changes to the machine. It projects visual information about expected chip removal and final dimensions onto the workpiece, allowing operators to verify settings before machining while maintaining relatively simple machine structure.
Solution Approach 2:
The laser projection system replaces the need for complex mechanical measurement and verification mechanisms. Instead of using physical gauges, calipers, or complex measurement devices to verify machine element settings, the system uses optical laser projection to visually display the expected machining outcome, simplifying the verification process.
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 operators to identify and correct machine settings before processing, significantly reducing workpiece waste by ensuring accurate machining dimensions and geometry, even with varying raw wood sizes and profiles.
Implementation Method 1
The molding machine (1) has a laser (18, 20, 23, 24) with which straight lines can be projected on the workpiece (1)
Data Source
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AI summary
The invention relates to a moulder that has a machine table (9) on which the workpieces (1) lie that are to be machined, and a truing table (2) on which the workpieces (1) are fed to said moulder. The moulder has horizontal and vertical spindles on which there are machining tools that machine the four sides of the workpiece (1) as it passes through the moulder. In order to avoid workpieces being wasted as a result of incorrectly-adjusted machine elements, or at least to keep such wastage to a minimum, the moulder is provided with at least two lasers (18, 20, 23, 24) the laser beams (19, 21, 26, 27) of which are directed towards the workpiece (1) situated on the truing table (2), producing straight lines on said workpiece (1). These indicate the amount of chip removal to be carried out on the workpiece (1) using the machining tools (5 to 7, 10), and therefore the workpiece dimensions and/or geometry to result from the subsequent machining. The one laser (18, 23) is coupled to, and can be adjusted with, one of the spindles, while another laser (20, 24) is arranged to be fixed in place. The laser beam (22, 27) thereof characterises the zero line of a stop (28) or the zero line of the machine table (9) as a straight line on the workpiece (1). The stop (28) forms a stop edge or a stop plane for the workpiece (1) as it is conveyed through the moulder. In this manner, the problem of workpieces being wasted as a result of incorrectly-adjusted machine elements can, at least, be kept to a minimum.