Local Robotic Panel Assembly Cells for Layered Wood Production
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Solution Overview
Problem
Current methods for producing layered wood products are inefficient, requiring extensive equipment, space, and human interaction, leading to inaccuracies in veneer grading and increased waste due to antiquated systems and high maintenance costs.
Innovation Solution
Implementing local robotic panel assembly cells with vision systems for veneer grading and robotic handling, eliminating the need for traditional conveyors and layup lines, allowing for independent assembly and grading of veneer sheets at pressing stations, and precise glue application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional conveyors and layup lines are used for veneer assembly, then veneer sheets can be transported and assembled, but the system requires extensive equipment, factory space, and human interaction, increasing complexity and operational costs
Solution Approach 1:
The patent replaces traditional mechanical conveyor systems and layup lines with robotic assembly cells equipped with vision systems. Robots autonomously handle veneer sheet positioning, grading, and assembly, eliminating the need for extensive mechanical transport infrastructure and reducing human interaction requirements.
Solution Approach 2:
The robotic assembly cells are designed to autonomously perform multiple functions including veneer handling, vision-based grading, glue application, and panel assembly without requiring human operators or extensive mechanical infrastructure. The system serves itself through integrated automation, reducing both equipment complexity and operational overhead.
2Ease of manufacture
If traditional conveyors and layup lines are used for veneer assembly, then veneer sheets can be transported and assembled, but the system requires extensive factory production space
Solution Approach 1:
The patent divides the traditional continuous conveyor system into discrete robotic assembly cells that can be positioned close to pressing stations. Each cell handles specific assembly tasks independently, eliminating the need for long continuous conveyors and reducing overall factory footprint while maintaining manufacturing capability.
Solution Approach 2:
The patent transitions from a linear, space-intensive conveyor-based assembly approach to a compact, multi-functional robotic cell configuration. By stacking functions vertically and positioning cells near pressing stations, the system reduces horizontal space requirements while maintaining ease of manufacture.
3Productivity
If antiquated systems are used for veneer grading, then grading can be performed, but inaccuracies occur and waste increases
Solution Approach 1:
The patent replaces antiquated mechanical grading systems with vision-based optical inspection systems mounted on robotic assemblies. These vision systems use cameras and image processing to accurately assess veneer quality, detect defects, and determine grading categories, significantly improving measurement precision over traditional mechanical methods.
Solution Approach 2:
The vision systems provide real-time feedback on veneer quality characteristics, enabling precise grading decisions. The system continuously monitors veneer sheets during assembly, compares them against quality standards, and adjusts grading assignments accordingly, reducing waste by accurately identifying usable versus defective material.
4Productivity
If traditional systems are used for glue application and panel assembly, then panels can be produced, but maintenance costs are high and operational efficiency is reduced
Solution Approach 1:
The patent combines glue application, veneer assembly, and panel formation into integrated robotic cells. The robotic systems perform multiple functions sequentially within a compact configuration, reducing the number of separate mechanical systems that require maintenance while improving operational efficiency through automation.
Solution Approach 2:
The patent replaces traditional mechanical assembly equipment with robotic systems that have fewer moving parts and lower maintenance requirements. The robotic arms, vision systems, and automated glue applicators require less frequent maintenance compared to conventional mechanical conveyors and assembly lines, improving ease of repair while maintaining high productivity.
Data Source
AI summary
A method and system for production of layered wood products employs local and independently operating robotic panel assembly cells including a vison system for inspecting and grading veneer sheets, one or more veneer handling robots, one or more core handling robots, and one or more glue application robots to produce stacks of layered wood product panels locally near the pressing stations. Consequently, the stacks of layered wood product panels are independently built at, or near, the location of the pressing stations using inspected and graded veneer sheets. This eliminates the need for traditional panel conveyors, traditional layered wood product panel assembly layup lines, and stack press delivery lines. This, in turn, eliminates thousands of moving parts and dozens of people from the layered wood product production process.