Veneer Sheet Alignment via Virtual Laser Edges
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Solution Overview
Problem
Current methods for aligning veneer sheets in LVL manufacturing are inefficient due to reliance on manual or mechanical alignment with limited precision, often resulting in suboptimal use of veneer surface area and visibility of defects, especially when using stationary fences.
Innovation Solution
A method that determines optimal positions for veneer sheets and virtual alignment edges, considering defects, allowing for precise alignment using laser lines or automated systems with cameras and grippers to maximize surface area utilization, with subsequent trimming to create real alignment edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual or mechanical alignment with stationary fences is used, then alignment operation is simple to perform, but alignment precision is insufficient and surface area utilization is suboptimal
Solution Approach 1:
The patent replaces traditional mechanical alignment fences with optical laser lines for alignment reference. The system uses laser projectors to create precise alignment lines that replace the need for physical mechanical fences, thereby improving alignment precision while reducing mechanical complexity
Solution Approach 2:
The patent creates virtual copies of alignment references through laser projection. Instead of using physical fences, the system projects laser lines that serve as virtual alignment guides, allowing for more precise and flexible alignment without the constraints of physical fence structures
2Productivity
If traditional alignment methods are used, then the process is easy to operate, but defects remain visible and surface area is not maximized
Solution Approach 1:
The system performs preliminary defect detection and analysis before the alignment operation. By identifying defects in advance and using this information to determine optimal alignment positions, the system ensures maximum surface area utilization while placing defects in cut-off zones, thereby improving productivity without complicating the actual alignment operation
Solution Approach 2:
The patent implements a feedback mechanism where defect detection results from imaging systems are fed back into the alignment positioning system. This feedback loop allows the system to automatically adjust alignment positions to maximize usable surface area while ensuring defects are positioned in areas that will be cut off, thereby improving productivity while maintaining ease of operation
3Reliability
If alignment is performed without considering defect positions, then the alignment process is simple, but defects are visible in the final product
Solution Approach 1:
The system performs preliminary scanning and defect detection before alignment. By identifying all defects in advance and planning the alignment position accordingly, the system ensures high product quality by guaranteeing defects will be in cut-off zones. This preliminary action approach maintains reliability while managing complexity through automated defect tracking
Solution Approach 2:
The patent uses feedback from defect detection systems to control the alignment positioning. The system continuously monitors defect positions and adjusts alignment accordingly, ensuring defects are always placed in optimal locations for removal. This feedback mechanism maintains high product quality while the automation manages the complexity of defect consideration
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
Enables precise and efficient alignment of veneer sheets, optimizing surface area usage and ensuring defects are cut off during trimming, improving the quality and efficiency of LVL production.
Implementation Method 1
The alignment can also be conducted in a totally visual manner by using e.g. laser lines as an alignment edge
Data Source
AI summary
The invention relates to a method for the optimal positioning of veneer sheets at a lay-up station, wherein the veneer sheets are attached for a veneer assembly composed of veneer sheets glued on top of each other. The method comprises determining an optimal position for each veneer sheet and a location for virtual alignment edges and laying up the veneer sheets as positioned in accordance with the virtual alignment edges, for a veneer assembly.