One-Pass Wide Dado Cutting for Scenic Flat Stud Boards

Solution Overview

Problem

Current methods for creating precise wide dado cuts across multiple boards are inadequate, especially in remote job sites, as they require multiple cuts, leading to errors and potential operator injuries, and existing saws struggle to support the necessary wide dado stacks.

Innovation Solution

An automated cutting system with a controller, sled unit, and wide one-pass dado blade assembly that cuts 3.5″ wide dadoes across multiple boards in one pass, using linear-bearing tracks and pneumatic sled actuators to ensure precision and safety, allowing for simultaneous cuts and minimal operator involvement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If multiple cuts are made to create wide dado cuts, then the cut width can be achieved, but the time required increases and the possibility of error increases

Engineering Contradiction:

Improvedado cut widthVSAvoidcutting time

Core Design Contradiction:

Length of moving objectVSLoss of time

Solution Approach 1:

The dado blade stack is segmented into multiple individual blades arranged in a stack configuration, allowing a single pass to create a wide cut equivalent to multiple sequential cuts. The stack includes a central blade and multiple outer blades positioned at specific intervals to create the desired dado width in one operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple cutting blades are merged into a single integrated dado blade stack assembly that operates simultaneously to produce the wide dado cut. This combines the function of multiple separate cutters into one unified tool that accomplishes the entire wide cut in a single pass through the workpiece.

Inventive Principle:

Principle #5Merging (Combining)

2Length of moving object

If multiple cuts are made to create wide dado cuts, then the cut width can be achieved, but the possibility of operator injury increases

Engineering Contradiction:

Improvedado cut widthVSAvoidoperator injury risk

Core Design Contradiction:

Length of moving objectVSObject-affected harmful factors

Solution Approach 1:

Multiple cutting blades are merged into a single integrated dado blade stack assembly that operates simultaneously to produce the wide dado cut. This combines the function of multiple separate cutters into one unified tool that accomplishes the entire wide cut in a single pass through the workpiece, reducing operator exposure to multiple cutting zones.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The complex multi-cut procedure is extracted and replaced by a single integrated dado blade stack operation. The need for multiple sequential cutting operations is eliminated by extracting the essential function into one specialized tool that performs the entire wide dado cut in a single pass.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If a very wide dado stack is used, then wide dado cuts can be made in one pass, but most present saws cannot support the mass and forces

Engineering Contradiction:

Improvecutting efficiencyVSAvoidsaw support capacity

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The dado blade stack is segmented into multiple individual blades arranged in a stack configuration, allowing a single pass to create a wide cut equivalent to multiple sequential cuts. The stack includes a central blade and multiple outer blades positioned at specific intervals to create the desired dado width in one operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The saw arbor and support system are designed with dynamic considerations to handle the mass and rotational forces of the wide dado blade stack. The arbor is adequately supported and braced to maintain stability during high-speed rotation under the increased load of the wide blade stack.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11890776B2Automated cutting for scenic flats construction

Publication Date: 2024.02.06 CRABB RANDY

AI summary

An automated cutting for scenic flats construction system and method for cutting of wide dadoes accurately spaced along sets of multiple boards to be used as studs or stiles for scenic flats, cleanly and accurately across the boards in one pass for each wide dado cut. A controller controls the automatic operation. A main unit with a support stand and a main-unit shell provides a sled unit extending and retracting along linear-bearing tracks by operation of sled actuators controlled by the controller. The sled unit provides a wide one-pass dado blade assembly capable of cutting a wide dado across multiple boards in one pass as the sled unit is moved along the linear-bearing tracks by the sled actuators under the control of the controller. After initial positioning of the set of uncut boards on an infeed table and against a positioning stop, the set of boards is held in place by hold-down clamps, the wide dado cut is made in one pass of the sled unit with the wide one-pass dado blade assembly, the hold-down clamps are released, the set of boards is moved through the main unit and toward a receiving table by a pre-set distance by a driving dog on a drive chain, the hold-down clamps are activated, and another wide dado cut is made in one pass, all under the control of the controller, repeating until all dado cuts are made to the set of boards.