Pinwheel Lumber Stacker for Truss Deck Alignment
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Solution Overview
Problem
Existing stack forming apparatuses are inefficient in rotating and stacking articles as a unit around a horizontal axis, particularly in handling dimensional lumber, leading to suboptimal processing in applications like truss making and stair stringer production.
Innovation Solution
A pinwheel assembly with radially recessed slots and a series of pusher dogs and a shuttle mechanism that rotates every 120° to efficiently stack and position boards on a saw deck, allowing for continuous processing and handling of multiple boards in a repetitive sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing stack forming apparatus is used to rotate and stack articles around a horizontal axis, then stacking function is provided, but processing efficiency is suboptimal and productivity is reduced
Solution Approach 1:
The apparatus is divided into distinct functional modules: a feed conveyor system for article input, a pinwheel assembly with radially recessed slots for article holding and rotation, and a pusher dog mechanism for stacking. This segmentation allows each component to perform its function efficiently while maintaining overall system productivity.
Solution Approach 2:
The pinwheel assembly rotates in periodic increments, with each rotation cycle performing a complete stacking operation. The repetitive rotational motion at 120° intervals enables continuous high-speed processing while maintaining precise control over article positioning and stack formation.
2Productivity
If articles are handled individually through existing apparatus, then stacking is achieved, but handling time increases and throughput decreases
Solution Approach 1:
Multiple articles are held simultaneously in the radially recessed slots of the pinwheel assembly, allowing parallel processing of multiple items within a single rotation cycle. This combining approach reduces total handling time while maintaining individual article control.
Solution Approach 2:
The feed conveyor continuously supplies articles to the pinwheel assembly, and the pinwheel rotates continuously in periodic increments, ensuring that the stacking operation proceeds without interruption. This continuous action maximizes throughput by eliminating idle time between stacking operations.
3Manufacturing precision
If conventional stacking apparatus is used, then basic stacking function is provided, but alignment precision and position control are insufficient
Solution Approach 1:
The radially recessed slots of the pinwheel assembly serve as an intermediary mechanism between the feed conveyor and the final stack position. These slots precisely position articles during rotation and transfer, ensuring accurate alignment and placement while the pusher dog completes the stacking action.
Solution Approach 2:
The pinwheel assembly dynamically rotates through controlled angular increments, allowing precise positioning of articles at different stages of the stacking process. This dynamic rotational motion provides superior position control compared to static or linear mechanisms.
Data Source
AI summary
A dimensional lumber stacker takes on plural boards in successive events from a feed group on one side of itself and then turns plural boards in unison about a horizontal axis and deposits them one the other side of itself, onto a deck. After which, the boards are urged away from the dimensional lumber stacker and across the deck as a unit, thereby separating from the dimensional lumber stacker and forming a stack as a consequence.