Panel Edge Milling Alignment for Accurate Locking Profiles
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Solution Overview
Problem
Existing methods for manufacturing panels with profiled edge areas, such as floor panels, face challenges in maintaining accuracy and design freedom, particularly with the risk of edge removal during milling operations, which limits the imitation of natural wooden floor panels.
Innovation Solution
A method involving the use of continuous milling machines with rotary tools to create mechanical coupling means like tongue and groove systems on panels, where the panels are fed in a fixed cross-position and orientation, determined by optical techniques, allowing for accurate profiling of both sides with profiled edge areas that include locking mechanisms, and a DPL laminate layer is applied without additional glue, ensuring stability and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If panels are milled with profiled edge areas using continuous milling machines, then mechanical coupling means can be created, but the risk of edge removal increases
Solution Approach 1:
The method determines the position and orientation of the lower edge area before the milling operation begins. By预先 identifying the location of the lower edge area using optical detection, the system can plan the milling path to avoid removing this critical edge portion, thus preventing edge removal while still creating the necessary profiled edge areas for mechanical coupling
2Manufacturing precision
If guide grooves are provided in panels to maintain accuracy, then positioning precision improves, but design freedom is limited
Solution Approach 1:
The invention replaces the mechanical guide groove system with an optical detection and measurement system. Optical detectors scan the panel to determine the position and orientation of the lower edge area, and this information is used to control the milling machine's positioning. This substitution eliminates the need for physical guide grooves, thereby maintaining positioning accuracy while preserving design freedom for various panel configurations and decorative patterns
3Reliability
If lower edge areas are modified to prevent removal, then edge stability improves, but aesthetic imitation of natural wood is compromised
Solution Approach 1:
The system uses optical detectors to scan the panel and determine the actual position and orientation of the lower edge area. This information is fed back to the control system, which adjusts the milling machine's positioning and cutting path in real-time. This feedback mechanism allows the system to mill profiled edge areas while automatically avoiding the lower edge area, thus maintaining both edge stability and the natural aesthetic appearance of the panel
Data Source
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AI summary
Method for manufacturing panels, wherein the panels (1A) concerned are subjected on at least one side (2-3; 4-5) to an operation (S1-S2) with cutting tools (6), characterized in that the position and/or orientation of each panel (1 A) is determined prior to the operation (S1-S2), and that the position and/or orientation of each panel (1A) is adjusted prior to the operation (S1) and/or the position of the tools (6) is potentially adjusted, such that at least one part of each panel (1A) concerned takes a fixed orientation and position in relation to said tools (6).