Virtual Lug Loader Conveyor Singulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lug loaders are inadequate at higher feed speeds and struggle to effectively singulate and allocate lumber of varying widths, thicknesses, and orientations, often requiring manual intervention and mechanical components that are difficult to maintain.
Innovation Solution
A transfer system utilizing conveyors to orient lumber transversely, with individually actuable pairs of endless conveyors that create consistent gaps and correct skew, allowing lumber to be directly loaded into lug spaces without mechanical intervention, improving speed and reducing maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional lug loaders use mechanical arms and clamps to singulate lumber, then lumber can be loaded into lug spaces, but the system becomes mechanically complex and difficult to maintain at high speeds
Solution Approach 1:
The patent replaces complex mechanical singulation mechanisms (rotating arms, clamps, and deflectors) with a simplified conveyor-based system. Individual conveyor belts transport lumber pieces directly to lug spaces, eliminating the need for mechanical manipulation devices and reducing maintenance requirements while enabling high-speed operation
Solution Approach 2:
The invention extracts the singulation function from the loading mechanism by using separate conveyor belts for each lumber piece. Each belt independently transports a lumber piece to its designated lug space, separating the transport function from the mechanical manipulation function and simplifying the overall system
2Ease of operation
If conventional lug loaders use fixed pick-up shoes on rotating discs, then lumber can be engaged and supported, but the shoes may mark the underside of finished boards
Solution Approach 1:
The patent replaces fixed pick-up shoes with continuous conveyor belts that support lumber from below throughout transport. This eliminates the mechanical contact points that cause marking, as the belts provide distributed support without concentrated pressure points that could damage finished board surfaces
3Productivity
If conventional lug loaders push the board mat back upstream to stop delivery, then the delivery mechanism can be stopped, but this is impractical at high speeds
Solution Approach 1:
The patent segments the continuous board mat into individual lumber pieces, each transported by its own conveyor belt. This allows independent control of each piece's delivery timing and position, enabling precise control at high speeds without the need to push the entire mat back upstream or stop the delivery mechanism
4Adaptability or versatility
If conventional lug loaders use rotating supporting arms with curved deflectors, then lumber can be singulated, but the system cannot effectively handle lumber of varying widths, thicknesses, and orientations at high speeds
Solution Approach 1:
The patent uses independently controllable conveyor belts that can dynamically adjust their speed and positioning to accommodate lumber of varying widths, thicknesses, and orientations. Each belt can be individually controlled to match the specific requirements of the lumber piece it carries, enabling high-speed operation with versatile handling capabilities
Data Source
AI summary
A virtual lug loader includes a lug loader for loading workpieces in a flow direction into the spaced apart lugs on a lugged conveyor, wherein the workpieces are transversely oriented relative to the flow direction. The lug loader includes an array of pairs of endless conveyors for conveying the workpieces downstream, wherein each pair of endless conveyors in the array include first and second endless conveyors. The first and second endless conveyors are spaced laterally apart across the flow direction. Each are aligned substantially in the flow direction. The array forms a continuous upper surface in the flow direction for supporting the workpieces translating downstream in the flow direction. Each pair of endless conveyors in the array overlap adjacent pairs of endless conveyors in the array. At least one pair of endless conveyors in the array include independently actuable first and second drives independently driving their corresponding first and second endless conveyors.