Apparatus and method of processing lumber

Abstract: This invention relates to a method and an apparatus for the cutting of dressed lumber to achieve the optimum value of cut pieces based upon the specific structural and surface defect characteristics of each board, as well as upon historical demand, business inventory and market factors. The invention includes the use of a Modulous of Elasticity test and photo-electric surface scanners in order to determine these specific structural and surface defect characteristics.

Description: This invention relates to a method and an apparatus for the cutting of dressed lumber to achieve the optimum value of cut pieces based upon the specific structural and surface defect characteristics of each board of dressed lumber, as well as upon historical demand, business inventory, and market factors. It is common practice to grade lumber using the human eye. This "visual" grading system attempts to determine the structural capabilities of a board by its apparent surface defects. The appearance of these defects thereby defines its grade. In Canada and the United States, visually graded lumber is classified into one of five distinct grades. Lumber which is to be used in structural applications must fall into one of the top three grades: namely, select structural; No. 1 grade; and, No. 2 grade. This traditional grading method is not precise, however, as apparent defects are often not actual defects that affect the structural capabilities of the lumber. Moreover, there are some defects within the lumber that are not apparent to the human eye. In visual grading, there are also inherent problems of human judgment. Thus, while the grading often results in lumber being graded less than its true grade, it can also result in lumber being graded better than its true grade. It is more common, however, for human graders using visual analysis to over-compensate for apparent defects and to undergrade the quality of the cut board. This discrepancy represents a significant cost to the lumber industry because the undergraded boards are sold for less money than their true value. In the past, primary lumber sawmills have attempted to overcome these problems of human visual grading by using a photo-electric scanning apparatus that assists in assessing a few of the specific surface defect characteristics of lumber such as "wane" and "knots". This method has hitherto been used only with "rough", not dressed, lumber. Generally, this method has involved moving, by conveyor, rough lumber pieces, which have just been cut, beneath an optical scanning system that measures the characteristics of light reflected from the lumber piece and translates these measurements as digitized signals, into a reading of the specific characteristics recognized from the surface of the lumber. While photo-electric scanning permits faster, and generally more accurate, analysis than by human visual grading, it remains subject to the problem that it is limited to identifying only the surface characteristics of the lumber. As a result, this method similarly tends to undergrade the quality of the lumber. In order to avoid the continued undergrading of lumber, it would be necessary to actually know how much weight, (ie. load) a board could carry before it would break. This, however, requires knowledge about the actual strength characteristics of the board along its entire length. The point at which a structural product, such as lumber, breaks is called its Modulous of Rupture (MOR). A non-destructive test to determine the rupture point of a board has not yet been found. However, it is known that there is a direct proportionate relationship between a board's ability to bend and the point at which it will break. The force required to deflect a board a pre-determined amount is called its Modulous of Elasticity (MOE). The MOE can therefore be measured in a non-destructive manner. Previously, the MOE test has only been used on visually graded finished pieces of lumber which have been determined to be structurally usable, so that the best, select pieces can be sorted out and sold at higher prices. In this application, only the average MOE for the entire board is considered. U.K. Patent Application No. GB 2,105,856 to Brooks et al. discloses an apparatus for determining the stiffness of timber and method of grading timber. The apparatus applies a load to a piece of lumber in order to produce a fixed deflection of the lumber. By correlating the load to the deflection, the lumber's stiffness is measured. Similarly, U.K. Patent Application No. GB 2,031,162 to Serry discloses improvements relating to the mechanical stress grading of timber. Serry discloses a method and apparatus for measuring the Modulous of Elasticity of timber by applying a load and measuring a corresponding deflection. For accuracy, Serry makes this measurement twice by applying the load to two of the sides of the lumber. Japanese Patent Application JP 58,208,643 to Nashiyonaru Jituutaku Sangyo discloses another apparatus using rollers to apply a load to a piece of wood, measuring the resulting deformation and thereby determining the wood's Modulous of Elasticity. U.S. Patent No. 3,941,019 to Baldwin et al. discloses a computer system to cut defects from lumber stock and thereby produce a maximum yield of different pieces cut from the stock. U.S. Patent No. 4,221,974 to Mueller et al. discloses a lumber inspection and optimization system which utilizes an electro optical scanner to detect flaws in a board. The system further uses a computer to produce flaw data and order entries to generate data indicative of where the board is to be cut. Martin et al. in the article "Automatisation dans l'industrie du bois" in Le Nouvel Automatisme , Vol. 27, No. 30, May 1982 reveals numerous lumber yield optimization systems which include hand marking of faults on tree trunks in conjunction with photo-electric detectors to determine optimal cuts. As well, the article reveals numerous other systems to grade lumber. Some such systems measure a lumber's resonance frequency, while others use gamma rays or microwaves to determine the lumber's density, nodes and Modulous of Elasticity in order to grade the lumber. The problem with the prior art, however, is that is does not provide a system that correlates "apparent" defects with a board's objective structural characteristics in order to achieve its most valuable use. Moreover, the MOE has not yet been used as a tool to test a piece of lumber to determine the cut pattern which would result in its maximum market value. As a result, individual pieces of lumber are usually sold below their optimum value as there has not been a method of grading which is "tolerant" of defects. By making the Modulous of Elasticity test on the lumber piece, the result of the Modulous of Elasticity test can be combined with the visual surface scan to reduce the likelihood of under-grading. The MOE test can be designed to provide digital output, and a computer can thus be programmed to control the cutting patterns of the lumber so as to achieve optimum quantity and value of the resultant pieces. Moreover, the computer can be programmed to find short pieces of a particular grade of lumber so as to there-by provide a high quantity of optimum graded lumber which can be jointed together without a loss of the structural characteristics. The concept of cutting lumber into high grade shortened pieces and joining the graded shortened pieces is of significant commercial value. Because of the apparatus required to measure the MOE of a piece of lumber, it is not possible to determine the MOE at either end of the piece (ie. usually the last 15.2 cm of each end of the board). By measuring the MOE continuously along the measurable length of the lumber and by combining this information with the information from the visual surface scan, a highly accurate approximation of the MOE for these "unmeasurable" ends of the lumber can therefore be extrapolated. It is an object of this invention to provide a method and apparatus that cuts finished lumber into pieces that yield dependable structural quality as well as optimum market value. It is an object of the invention to make use of the Modulous of Elasticity test along the length of a piece of lumber with a view to achieve, by cutting, the most profitable yield of the resultant pieces. It is also an object to make use of a measurement of visual characteristics of the surface of a piece of lumber in combination with the Modulous of Elasticity to achieve the most profitable yield of pieces, graded to objective standards. By combining the values of these two measurements, the yield of highest value cut lumber pieces is introduced. It is a further object of the invention to provide a computerized grading method of lumber which is optimally tolerant of defects in the lumber. According to an aspect of the present invention, there is provided a method of cutting a piece of lumber, said piece of lumber having a surface, characterized in that said method comprises the steps of: obtaining structural characteristics and capabilities information for said piece of lumber by taking modulous of elasticity measurements along the length of said piece of lumber; obtaining possible structural defects information for said piece of lumber by photoelectrically scanning said surface of said piece of lumber for visual markings; determining a cutting pattern for said piece of lumber based upon said structural characteristics and capabilities information, said possible structural defects information and pre-determined parameters; cutting said piece of lumber in accordance with said cutting pattern. According to another aspect of the present invention, there is provided an apparatus for cutting a piece of lumber, said piece of lumber having a surface, characterized in that said apparatus comprises: a computer; a first station for obtaining structural characteristics and capabilities information for said piece of lumber by taking modulous of elasticity measurements along the length of said piece of lumber and sending said structural characteristics and capabilities information to said computer; a second station for obtaining possible structural defects information for said piece of lumber by photoelectrically scanning said surface of said piece of lumber for visual markings and sending said possible structural defects information to said computer; and a third station for cutting said piece of lumber in accordance with a cutting pattern sent by said computer, said computer receiving said structural characteristics and capabilities and possible structural defects information from said first and second stations and determining a cutting pattern for said piece of lumber based upon said structural characteristics and capabilities information, said possible structural defects information and pre-determined parameters and sending said cutting pattern to said third station. The invention will be readily understood after reading the following description given in conjunction with the drawings in which: Figure 1 is a schematic side elevation of an apparatus for practising the invention; Figure 2 is a schematic block diagram showing the computer interface system of an apparatus for practising the invention; Figure 3 is a schematic block diagram of an apparatus for practising the invention; Figure 4 is a schematic illustration of the testing apparatus at the MOE measuring station; Figure 5 shows the top surface, the worst face, of a piece of lumber of the type that can be cut with this invention; Figure 6 shows the piece of lumber of Figure 5 cut into the pieces directed by the computer system; Figure 7 shows the top surface of another piece of lumber of the type that can be cut with this invention; and, Figure 8 shows the piece of lumber of figure 7 cut into the pieces directed by the computer system. Figure 1 is a schematic side elevation of an apparatus for practising the invention. This apparatus has a conveyor 10 for conveying monitored pieces of dressed lumber 12, similar to that shown in Figures 5 and 7, to a MOE measuring station 16, to a second conveyor 17, then to a surface scanning station 18, then to cutting stations 20, and then to a sorting and stacking area or station which is generally indicated by the numeral 22. Each piece of lumber 12 stops at the MOE measuring station 22. Each piece of lumber 12 stops at the MOE measuring station 16, the surface scanning station 18 and the cutting stations 20, and then to a sorting and stacking area generally indicated by the numeral 22. At the MOE station 16 the modulous of elasticity of each board is measured when the conveyor stops at the station. The MOE of a lumber piece, as determined between spaced apart points along its length, is an important characteristic of the lumber for grading purposes. The MOE is represented by the formula: where: E = MOE, units can be expressed in Pa; F = applied force at the centre of the span, units can be expressed in N; L = length of span, units can be expressed in m; D = displacement by force at the centre of the span, units can be expressed in m; W = width of the lumber piece, units can be expressed in m; and H = thickness of the lumber piece, units can be expressed in m; It has been found useful in determining an efficient cut pattern for a piece of lumber to measure E with an L of approximately 0.6096 m along the length of a piece of lumber. The length of the lumber piece in practise will be more often between 2.438 m and 7.315 m. Height and width for a piece of lumber 12 will be substantially constant and usually in the order of 10 - 30 cm width and 2.5 - 1.25 cm height, respectively. In the test described herein, a force F is applied to achieve a constant deflection D of about 1.6 mm for a 2.5 - 1.25 cm thick piece of lumber 12. The variable is the applied force F and this variable is measured continuously along the length of the lumber as it is moved through the MOE measuring station 16. The resistance of the board to the applied force (ie. deflection) is measured and is fed into a computer system 24 to assist in determining the desired cutting pattern for the board, as will be described later. Figure 4 is a schematic illustration of the testing apparatus at the MOE measuring station 16. The apparatus includes sets of clamping rollers generally indicated by the numerals 26 and 28. These rollers are designed to support the length of lumber between them and to move the lumber 12 along the conveyor. As the lumber moves through the MOE measuring station 16, it is deflected a constant amount D by the roller 30. Depending on the MOE of the lumber between the rollers, the force F required to maintain the constant deflection will vary. This reading of resistance to this force is, as noted above, transmitted to the computer system 24 and is a useful characteristic in determining the optimum cut pattern for the lumber. Measurements E are made continuously and the results are integrated over each 2.5 cm of the lumber, or some other arbitrarily chosen length, for the purposes of computer system input. The lumber 12, on leaving the MOE measuring station 16, is received by conveyor 17 and proceeds to the surface scanning station 18. The surface scanning station 18 scans a surface of the piece of lumber 12 for surface markings. This is achieved by transmitting light onto the top and edge surfaces and photo-electrically reading the reflected light to determine surface marking variations. For example, a black knot is relatively dark and will therefore generally absorb light. Accordingly, as little of the transmitted light is reflected, the photo-electric scanner would optically "read" or detect the presence of the knot. The surface scanning means typically includes a set of cameras whose field of vision overlap with one another. Analog/digital processors are also provided for processing the information gathered by the cameras. A surface scanning means found to be suitable for this invention is the Dendro Maskin 4000™, manufactured by Dendro Maskin™. In the Dendro Maskin 4000™, each camera includes approximately 1,000 diodes. By controlling the lights when the picture is taken, each of the diodes in each camera will measure an exclusive area on the lumber piece of about 2 X 2 mm. In use, the piece of lumber is positioned in front of the lens of the cameras. The piece is suitably lighted and a picture is taken of the whole exposed surface of the lumber piece. The process is synchronized by a master processor which is able to determine the location of blemishes, markings or knots on the lumber piece. Figure 5 shows a typical lumber piece 32. Formed on the lumber piece 32 is a black knot 34 with a diameter of 5 cm, and its centre is located 190.5 cm from the back edge and 2.5 cm from the side edge 36. The black knot 34 would therefore likely fall within the confines of a grouping of nine of the 2 X 2 mm area sections. The data sent to the computer system 24 from the surface scanning station would indicate that those nine 2 X 2 mm sections have a dark spot therein. The computer system 24 combines this information with the information obtained by the MOE reading station 16. Therefore, assuming that the MOE reading for the length of the lumber is low (ie. it takes a relatively small force to achieve the pre-determined constant deflection), the computer system 24 would confirm that the mark is more than a surface mark and is one that affects its structural strength. On the other hand, if the value of E remained high at the location of the apparent black knot, it would indicate that it is only a surface blemish that does not affect the structural strength of the lumber. Looking at Figure 5, a dotted area 38 indicates an area of decay in a typical piece of lumber. An area of decay would not necessarily be detected by the surface scanning station 18, but its weakening effect would should up on the data produced by the MOE measuring station 16. The length of the lumber piece for which there is decay would result in a computer output indicating removal of that section. Having combined the information gathered by the MOE measuring station 16 and the surface scanning station 18, the computer system 24 operates the cutting stations 20 to cut the lumber into pieces of optimum value. In particular, the lumber may be cut horizontally (a "rip" pattern) or vertically (a "trim" pattern) and one cutting station 20 may be exclusively employed for trimming of lumber while the other cutting station 20 is employed for ripping. The cutting stations 20 can be of the standard design used in the trade to effect a trim and/or rip of the lumber in the usual manner, but in accordance with the computer output from the computer system 24. The computer can be programmed to trim and rip according to any grading standard and to favour output of any particular grade and dimension combination according to current market value, and/or historical demand or open order requirements. The computer system 24 can also be programmed to cut the lumber into non-standard lengths as required and it can be programmed to send the cut lumber into these appropriate storage bins. The piece of lumber shown in Figure 5 could therefore be cut into pieces of lumber 52, 53, 54, 55 and 56, as shown in Figure 6. Similarly, the lumber piece 39 shown in Figure 7 having split 40, black knot 42 and decayed portions 44 could be cut into graded pieces 46, 48, 50 and 52, as shown in Figure 8. It is also significant that pieces of lumber may be joined by a finger jointing technique. By joining structurally sound shorter pieces, one can therefore get a greater yield of longer pieces of lumber of increased value. Finger jointed lumber is widely used in Europe and in some parts of the United States. Finger jointed lumber has been found to meet, and for some applications surpass, the average strength criteria of non-jointed pieces of similar grade cut lumber. This system can locate short lengths of cut lumber and direct them for wood fibre recovery by finger jointing. For example, although 2.438 m is commonly a standard length of cut lumber, there may not be very many 2.438 m lengths of grade A lumber pieces recoverable from the lumber being used. However, there would, of course, be a greater number of shorter lengths of grade A lumber available. This system can therefore request Grade A lumber which is as short as 15.2 cm in length, locate and cut them, and then recover them for finger jointing. A finger jointing station is indicated by the numeral 25 in Figure 3, and is coordinated by the computer system 24. An overview of the computer system 24 is illustrated in Figure 2 which is a schematic diagram of the system's interfaced network. There are three major information transfers in the network. The first transfer of information is carried out when the off-line expert system 102 interacts with both the on-line expert system 100 and the plant's information system 104. The on-line expert system is a combination of computer hardware and software while the plant's information system 104 includes a listing of open orders, prices of the different grades of wood, historical production information, and inventory. The off-line expert system 102 accesses the information in the plant's information system 104 and is able to, on the basis of programmed parameters, assign a priority as to what sizes and grades of wood are the most desirable to cut. The off-line expert system 102 feeds the on-line expert system 100 the priority information on a periodic basis, for example once every shift. The second transfer of information is carried out when the MOE measuring means and the surface scanning station 18 each analyze the lumber piece and send the data via the communication transfer interface 106 and the Programmable Logic Controller ("PLC") 108 to the on-line expert system 100. The third transfer of information is carried out when the on-line expert system 100 matches the information sent to it from the off-line expert system 102 with the information sent to it from both the MOE measuring means and the surface scanning station 18, in order to determine an optimum trim and/or rip pattern. Moreover, the off-line expert system plays an important role in the manufacturing process as it not only determines what lumber storage bins are available, but it also determines what lengths of lumber should be cut to accommodate those storage bins. As well, the off-line expert system responds to the programmed parameters and to historical demand, business inventory, open orders and market factors so as to pre-determine the amount of raw lumber required for cutting the optimum number of pieces of lumber of optimum value. As a result, the computer system 24 is not only able to assign a priority as to what sizes and grades of lumber are most desirable, but it also ensures that the desired volumes, sizes and grades of lumber can practically and properly be handled and stored. The cutting stations 20 can then respond accordingly to the digital instructions forwarded by the on-line expert system. The computer system 24 identifies this cutting plan to a human quality control operator who can choose either to accept or to reject this plan. The computer then instructs the cutting stations 20 via the Programmable Logic Controller ("PLC") 108 to execute its choice. The PLC controller is the apparatus by which the on-line expert system 100 controls computer-controlled apparatus. The PLC controllers are dedicated to controlling external events, as instructed, and to relaying information back to the on-line expert system 100. The computer-controlled ("CC") devices receive data from the PLC Controller 108 and act on that data and/or transmit to the PLC Controller after an apparatus event. For example, the speed at which the conveyor system runs, as instructed by the on-line expert system via the PLC Controller 108, would be sent through CC devices. Similarly, the cutting mechanisms would be controlled via CC devices. The PLC Controller 108 is interfaced to the MOE measuring station 16, the surface scanning station 18 and the other networked CC devices 21. The interface ensures that the instructions are properly transferred from the PLC Controller 108 to its correct destination. An operator console 110 provides an override function and a rest function. Over-ride is required when the system jams or is unduly slowed down because of an overly defective piece of lumber that cannot be processed by the apparatus. The operator can override the computer system by rejecting the lumber piece via the rejection station 23. The reset function of the operator console is used to correct system confusion, which might result from a misaligned, or jammed, piece of lumber.

Claims: A method of cutting a piece of lumber (12), said piece of lumber having a surface, characterized in that said method comprises the steps of: obtaining structural characteristics and capabilities information for said piece of lumber by taking modulous of elasticity measurements (16) along the length of said piece of lumber; obtaining possible structural defects information for said piece of lumber by photoelectrically scanning (18) said surface of said piece of lumber for visual markings; determining a cutting pattern for said piece of lumber based upon said structural characteristics and capabilities information, said possible structural defects information and pre-determined parameters; cutting (20) said piece of lumber in accordance with said cutting pattern. The method as claimed in claim 1 wherein said pre-determined parameters include an optimum number of cut pieces of optimum value. The method as claimed in claim 1 wherein said pre-determined parameters include market value of said cut pieces. The method as claimed in claim 1 wherein said pre-determined parameters include specific dimensions dictated by inventory requirements. The method as claimed in claim 1 wherein said pre-determined parameters include an optimum quantity of graded pieces of cut lumber of dependable structural strength regardless of the length of said cut pieces. The method as claimed in claim 1 wherein said pre-determined parameters include specific desired dimensions of cut lumber pieces and a desired amount of pieces of lumber to be cut. The method as claimed in any one of claims 1 to 6 wherein said modulous of elasticity measurements are taken at a first station (16); said surface of said piece of lumber is photoelectrically scanned at a second station (18); and said piece of lumber is cut at a third station (20). The method as claimed in claim 7 wherein said piece of lumber is moved to said first station along a conveyor means (10); said piece of lumber is moved from said first station to said second station along a conveyor means (10); and said piece of lumber is moved from said second station to said third station along a conveyor means (10). The method as claimed in claim 7 further including the steps of sending said structural characteristics and capabilities information derived from said modulous of elasticity measurements from said first station (16) to a computer (24); sending said possible structural defects information derived from photoelectrical scanning from said second station (18) to said computer; comparing said information with said pre-determined parameters by said computer to determine said cutting pattern for said piece of lumber; determining cutting instructions in accordance with said cutting pattern; sending said cutting instructions from said computer to said third station (20); cutting said piece of lumber according to said cutting instructions at said third station. The method as claimed in any of one of claims 1 to 9 wherein said modulous of elasticity measurements are taken by determining a magnitude of force which must be applied to said piece of lumber between two separated fixed points to maintain a constant deflection of said piece of lumber between said two separated fixed points. The method as claimed in any one of claims 1 to 10 wherein said cut pieces of lumber may be jointed together where they are of a like grade. An apparatus for cutting a piece of lumber (12), said piece of lumber having a surface, characterized in that said apparatus comprises: a computer (24); a first station (16) for obtaining structural characteristics and capabilities information for said piece of lumber by taking modulous of elasticity measurements along the length of said piece of lumber and sending said structural characteristics and capabilities information to said computer; a second station (18) for obtaining possible structural defects information for said piece of lumber by photoelectrically scanning said surface of said piece of lumber for visual markings and sending said possible structural defects information to said computer; and a third station (20) for cutting said piece of lumber in accordance with a cutting pattern sent by said computer, said computer receiving said structural characteristics and capabilities and possible structural defects information from said first and second stations and determining a cutting pattern for said piece of lumber based upon said structural characteristics and capabilities information, said possible structural defects information and pre-determined parameters and sending said cutting pattern to said third station. The apparatus of claim 12 wherein said pre-determined parameters include an optimum number of cut pieces of optimum value. The apparatus of claim 12 wherein said pre-determined parameters include market value of said cut pieces. The apparatus of claim 12 wherein said pre-determined parameters include specific dimensions dictated by inventory requirements. The apparatus of claim 12 wherein said pre-determined parameters include an optimum quantity of graded pieces of cut lumber of dependable structural strength regardless of the length of said cut pieces. The apparatus of claim 12 wherein said pre-determined parameters include specific desired dimensions of cut lumber pieces and a desired amount of pieces of lumber to be cut. The apparatus in any one of claims 12 to 17 comprising an operator console (110) for either resetting said apparatus as a result of a jam or for removing an undesirable piece of lumber from said apparatus. The apparatus of any one of claims 12 to 18 wherein said first station (16) comprises a means for measuring the modulous of elasticity along the length of said piece of lumber which includes a plurality of rollers (26, 28, 30) to deflect said piece of lumber (12) between two separated fixed points (26, 28) and means for determining the magnitude of force required to maintain said deflection. The apparatus of any one of claims 12 to 19 comprising a finger jointing station (25) for jointing two cut lumber pieces.

Inventors: CZINNER ROBERT L, CZINNER, ROBERT L.
Applicants: CZINNER ROBERT L, CZINNER, ROBERT L.
Application year: 1989
Main classification: G01N33
IPC codes: B26D5, G06Q10, B27G1, B27B1, B23D59, G01N33