Panel Edge Milling with Optical Alignment for Accurate Coupling Profiles
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Solution Overview
Problem
Existing methods for manufacturing panels, such as floor panels, face challenges in accurately forming profiled edge areas with mechanical coupling means, particularly in maintaining the design freedom and accuracy of the panel edges during milling operations.
Innovation Solution
The method involves determining and adjusting the position and orientation of each panel prior to the cutting tool operation, ensuring that specific parts of the panel, like the lower edge area, are in a fixed orientation and position relative to the tools. This allows for precise operations, such as milling, to be performed at an accurate distance from these parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If panels are transported through continuous milling machine by means of chain with cams, then productivity is improved, but manufacturing precision deteriorates due to difficulty in maintaining accurate position and orientation
Solution Approach 1:
The patent replaces the mechanical chain-and-cam positioning system with an optical measurement system (cameras or scanners) that detects panel position and orientation, followed by automated adjustment mechanisms. This substitution allows high-speed transport while maintaining precision through electronic control rather than mechanical constraints.
Solution Approach 2:
The patent performs position and orientation determination before the milling operation, allowing preliminary adjustments to be made. This ensures that when the panel enters the milling zone, it is already properly positioned, eliminating the need for complex real-time mechanical positioning during high-speed transport.
2Manufacturing precision
If guide groove with guide knife is used to maintain accuracy at high throughput speeds, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces the mechanical guide groove and guide knife system with an optical detection system (cameras or scanners) combined with automated positioning adjustments. This reduces mechanical complexity while maintaining or improving positioning accuracy through electronic measurement and control.
Solution Approach 2:
The patent introduces an intermediary measurement system (optical sensors, cameras, or scanners) that detects panel position and orientation without physical contact. This intermediary allows accuracy to be maintained through information-based control rather than direct mechanical guidance.
3Reliability
If lower edge area geometry is modified to minimize risk of removal during milling, then reliability is improved, but design freedom deteriorates
Solution Approach 1:
The patent determines the position and orientation of the lower edge area before the milling operation and makes preliminary adjustments to ensure it remains in a fixed, protected position relative to the cutting tools. This allows the original lower edge geometry to be preserved while still preventing accidental removal during milling.
Solution Approach 2:
The patent implements a feedback system where the position and orientation of the panel are continuously monitored (using cameras or scanners), and adjustments are made based on this feedback to maintain the lower edge area at a safe distance from the cutting tools, thereby protecting it while allowing design freedom.
Data Source
AI summary
A method for manufacturing panels such that the panels are subjected on at least one side to an operation with cutting tools. The position and/or orientation of each panel is determined prior to the operation, and the position and/or orientation of each panel is adjusted prior to the operation and/or the position of the tools is potentially adjusted, such that at least one part of each panel concerned takes a fixed orientation and position in relation to the tools.