Timber Stacking Device with Sensor-Driven Optimization
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Solution Overview
Problem
The existing stacking processes for lumber, particularly for untrimmed timber, are inefficient and require manual intervention, leading to suboptimal stacking quality and stability due to the need for manual assessment and arrangement of boards post-drying, which is time-consuming and labor-intensive.
Innovation Solution
A stacking device equipped with a conveyor unit, sensor unit, optimization computer, and lifting/swiveling device that records timber dimensions and quality parameters, determines optimal stacking configurations, and automates the placement of timber into stacks, ensuring homogeneous and stable stacking through data-driven decision-making.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assessment and arrangement of boards is used post-drying, then flexibility in quality assessment is maintained, but productivity is reduced and time consumption increases
Solution Approach 1:
The patent replaces manual mechanical assessment and stacking with an automated optical-mechanical system. Sensors scan the wood stacks to automatically detect board ends, measure dimensions, and identify quality characteristics, eliminating the need for manual visual inspection and physical handling while maintaining accurate quality assessment.
Solution Approach 2:
The system enables the stacking process to self-regulate by automatically detecting board characteristics and adjusting stacking parameters without human intervention. The control unit processes sensor data to determine optimal stacking arrangements, automatically controlling the stacking mechanism to place boards in the most stable and space-efficient configurations.
2Manufacturing precision
If manual stacking is performed, then adaptability to varying wood qualities is maintained, but manufacturing precision of stack arrangement deteriorates
Solution Approach 1:
The patent employs optical sensors and automated control systems to replace manual stacking operations, achieving precise measurement of board dimensions and automatic calculation of optimal stacking arrangements. This mechanical-to-optical substitution enables sub-millimeter precision in stack arrangement that exceeds manual capabilities.
Solution Approach 2:
The system continuously scans the wood stack during the stacking process, detecting board characteristics and comparing them against optimal stacking criteria. The control unit receives real-time feedback from sensors and automatically adjusts the stacking mechanism to correct any deviations from the optimal arrangement, ensuring high precision throughout the stacking process.
3Productivity
If automated stacking is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The patent designs a multi-functional stacking device that combines scanning, measurement, quality assessment, and stacking operations into a single integrated system. The same mechanical arm and sensor array that detect board characteristics also perform the stacking operation, eliminating the need for separate manual operations and reducing overall system complexity despite the advanced automation capabilities.
Solution Approach 2:
The system merges the assessment and stacking functions into a unified automated process. The sensors that detect board dimensions and quality characteristics are integrated with the control unit that determines stacking arrangements, which in turn directly controls the stacking mechanism. This consolidation of functions into a single coordinated system improves productivity while managing device complexity through integration.
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
The solution significantly automates the stacking process, improving the efficiency and quality of lumber stacks by optimizing the arrangement of timber based on quality and dimensions, reducing the need for manual labor and enhancing the stability and homogeneity of the final product.
Implementation Method 1
sensor unit which records the timber dimensions and quality parameters
Implementation Method 2
lifting device which removes the timber from the conveyor and places it in a storage area
Implementation Method 3
swiveling device which swivels the lifting device in order to optimally orient the timber with respect to the stack
Implementation Method 4
optimization computer with which the sensor unit is in data connection, which removes the timber from the conveyor and places it in a storage area
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The piling device has a conveyor unit (1) for conveying an isolated sawn timber (2). A sensor unit (3) is assigned for detecting a wood mass or defined quality parameter. The sensor unit is provided for connecting with an optimizing computer (4) in a data transferring mode. A buffer point is provided downstream to the sensor unit in conveying direction of the sawn timber for time to time stockpiling of the supplied sawn timber by the running conveyor unit. The buffer point has a traveling crane that is arranged transverse to the conveying direction of the sawn timber. An independent claim is included for a method for manufacturing a piling device.