Patent Publication Number: US-10780604-B1

Title: Automated multi-headed saw for lumber and associated method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/658,026, filed Jul. 24, 2017 by Steven R. Weinschenk, titled “AUTOMATED MULTI-HEADED SAW AND METHOD FOR LUMBER” (which issued as U.S. Pat. No. 10,207,421 on Feb. 19, 2019), which claims priority benefit, under 35 U.S.C. § 119(e), of U.S. Provisional Patent Application 62/495,830, filed Sep. 26, 2016 by Steven Weinschenk, titled “MULTI-HEADED LINEAR SAW,” each of which is incorporated herein by reference in its entirety. 
     This invention is related to:
         U.S. Provisional Patent Application 62/388,048, filed Jan. 14, 2016 by Steven Weinschenk, titled “AUTOMATED SYSTEM AND METHOD TO ENHANCE SAFETY AND STRENGTH OF WOOD TRUSS STRUCTURES,”   U.S. patent application Ser. No. 15/408,369, filed Jan. 14, 2017 by Steven Weinschenk, titled “AUTOMATED SYSTEM AND METHOD TO ENHANCE SAFETY AND STRENGTH OF WOOD TRUSS STRUCTURES” (which issued as U.S. Pat. No. 10,239,225 on Mar. 26, 2019).   U.S. patent application Ser. No. 15/408,374, filed Jan. 14, 2017 by Steven Weinschenk, titled “AUTOMATED SYSTEM AND METHOD FOR LUMBER ANALYSIS” (which issued as U.S. Pat. No. 10,580,126 on Mar. 3, 2020),   U.S. patent application Ser. No. 15/426,966, filed Feb. 7, 2017 by Steven Weinschenk, titled “AUTOMATED SYSTEM AND METHOD FOR LUMBER PICKING” (which issued as U.S. Pat. No. 10,493,636 on Dec. 3, 2019),   U.S. Provisional Patent Application 62/144,859 filed Apr. 8, 2015 by Steven Weinschenk, titled “DIGITAL PROJECTION SYSTEM AND METHOD FOR WORKPIECE ASSEMBLY,” and   U.S. patent application Ser. No. 15/093,732 filed Apr. 7, 2016 by Steven R. Weinschenk et al., titled “DIGITAL PROJECTION SYSTEM AND METHOD FOR WORKPIECE ASSEMBLY” (which issued as U.S. Pat. No. 10,210,607 on Feb. 19, 2019); each of which is incorporated herein by reference in its entirety.       

    
    
     FIELD OF THE INVENTION 
     The present invention relates to devices and methods to workpiece assembly, and in particular to automated multi-headed saw systems and methods for lumber sawing that use two single-contact-point “fence posts” that are optionally associated with and move with each one of a plurality of saw heads in order to securely hold and support boards that may have curved sides (due to crooks or warps), rather than boards having straight sides aligned along a straight-wall conventional saw fence. Some embodiments organize each incoming stack of lumber in one of a plurality of vertically spaced apart bunks, one on top of another, and provide a gantry that picks a selected board from the stack of lumber on a selected bunk, and moves the board in a direction generally perpendicular to the long axis of the board from the selected bunk to one of possibly multiple copies of the multi-headed sawing station, thereby shortening the distance traveled between the bunks and the saws. Some embodiments further include a conveying mechanism that moves the cut boards to a truss-assembly table, where a product such as a truss or stud-wall section is finished. 
     BACKGROUND OF THE INVENTION 
     One problem with today&#39;s conventional technology is that, when manually loading wood into the infeed systems, the human operator needs to determine how to orient the wood, which increases the cost of labor when manufacturing structures using wood boards (lumber). As used herein, “crook” is a lumber feature or defect where the widest faces of the piece of lumber are substantially planar but there is a curvature along the length of the narrower faces of the piece of lumber. The “crown” is the convex one of the narrower faces of the piece of lumber with a crook. The crown should be orientated to optimize with the wood saw equipment. Certain wood trusses and pre-assembled walls are more secure if the crown of the wood is oriented correctly (both when the board is loaded into a sawing station, and when the cut board is assembled into a truss, a pre-assembled wall, or the like). Conventional automated or partially automated systems are unable to determine and/or distinguish the crown of the lumber. 
     U.S. Pat. No. 4,196,648 to Jones, et al. issued on Apr. 8, 1980 with the title “Automatic sawmill apparatus” and is incorporated herein by reference. U.S. Pat. No. 4,196,648 describes a cant or plank is moved forwardly on a conveyor system, where its irregular leading lateral edge is measured by a plurality of fixed scanners. In response to measurement of the cant, conveyor movement is altered for orienting the cant relative to a fixed saw line to be executed by a movable saw. The cant is held or clamped in stationary position while the saw is moved on a carriage relative thereto, resulting in severing of the undesired irregular forward edge. The sawn edge is employed as a reference as the cant is then moved forwardly on a conveyor system, where the measurements obtained from the scanners may be further utilized in cutting the cant into desired widths. 
     U.S. Pat. No. 4,909,112 issued to Rosenthal on Mar. 20, 1990 with the title “Multiple head gang saw with simplified, accurate displacement transducer,” and is incorporated herein by reference. U.S. Pat. No. 4,909,112 describes a multiple head gang saw has a plurality of moveable saw heads providing variable width cutting, and a single magnetostrictive displacement transducer sensing displacement of all of the saw heads. The transducer sender unit is mounted to a transverse cross beam, and a magnetostrictive rod extends from the sender unit along and parallel to the cross beam. A plurality of pairs of electromagnets are mounted to respective saw heads proximate the magnetostrictive rod. Switching circuitry selectively energizes a chosen electromagnet pair and de-energizes the remaining electromagnet pairs such that only the chosen electromagnet pair generates a magnetic field interacting with the signal in the rod from the sender unit, such that the displacement transducer indicates the distance from the sender unit to the chosen electromagnet pair and its respective saw head along the cross beam. 
     United States Patent Publication 2005/0027389 by Hadaway et al. published on Feb. 3, 2005 with the title “Computer numerically controlled table saw fence” and is incorporated herein by reference. Publication 2005/0027389 describes a table saw control system. The system shortens the time required to learn how to operate a table saw, eliminates the necessity of making conversions from one measurement system or unit to another, reduces the likelihood of error occurring during the use of a table saw, and makes a table saw safer to use. The system includes a touch control screen mounted on the fence and moving simultaneously with the fence; and, a plurality of inter-related operational menus operatively associated with the computer and displayed sequentially on the screen and including button images activated by touch to generate signals to the computer to move from one of the menus to another of the menus and to control movement of the carriage and the fence. 
     U.S. Pat. No. 4,951,215 to Scherer issued on Aug. 21, 1990 with the title “Lineal output measurement circuit for use with product cutting apparatus” and is incorporated herein by reference. U.S. Pat. No. 4,951,215 describes a lineal output measurement circuit adapted for use with product cutting apparatus, primarily with wood cutting apparatus of the type which have a plurality of simultaneously operable cutting elements. This product cutting apparatus is thereby capable of cutting product stock, such as ripping of a wood member simultaneously into individual wood section strips with a plurality of saw blades positioned to cut the individual strips. The apparatus generally includes some form of input mechanism for programming the cutting mechanism to produce the individual sections of product, that is, to produce the desired amount of the selected widths of product. The measurement circuit of the present invention utilizes program electrical signals from the apparatus which provide a program input representative of the different sizes of product sections to be produced, along with a port circuit and a processing means. The processing means calculates the amount of product sections cut from the product stock and generates output signals therefor. 
     U.S. Pat. No. 8,010,216 to Roise issued on Aug. 30, 2011 with the title “System and method for cutting-stock optimization across schedules and batches” and is incorporated herein by reference. U.S. Pat. No. 8,010,216 describes a method and system for optimizing cutting of various materials. In some embodiments, an algorithm optimizes cutting by grouping items to be cut, wherein two or more of a plurality of cutting-stock pieces are grouped together and aligned such that a single cut simultaneously cuts items from all of the pieces. Some embodiments optimize a combination of reduced labor cost, reduced materials cost (e.g., reducing scrap), and/or reduced time needed to obtain an inventory of pieces cut to specified lengths and shapes (checking the various permutations). Overall optimization of labor and material is achieved by a combination of fewer cuts and reduced waste. Some embodiments include a computer-readable medium having instructions executed by a computer that optimizes placement of cuts to obtain cut-part items, and optionally controls a saw, laser, water-jet cutter or the like. In some embodiments, a human operator making the cuts is instructed by the computer to achieve the optimization. 
     U.S. Pat. No. 6,170,163 to Robert A. Bordignon et al. titled “METHOD OF ASSEMBLING COMPONENTS OF AN ASSEMBLY USING A LASER IMAGE SYSTEM,” issued Jan. 9, 2001, and is incorporated herein by reference. In U.S. Pat. No. 6,170,163 Bordignon et al. describe a method of assembling components of an assembly, such as the components of a truss, using a laser imaging system in combination with assembly jigs. The jigs may be slideably mounted on an assembly table wherein the jigs include laser alignment indicia on a top surface of the jigs spaced a predetermined distance from a side surface of the jigs. The method includes projecting an enlarged laser generated outline of at least a portion of the components to be assembled which is spaced laterally from an outline or template of the components in the assembled position a distance equal to the distance between the laser alignment indicia and the side surface of the jigs and spaced vertically a distance equal to the distance between the indicia and the work surface. The jigs are then moved on the work surface to align the laser alignment indicia with the enlarged outline and affixed relative to the work surface. Finally, the components are assembled on the work surface in generally abutting relation with the side surfaces of the jigs and assembled. Where the assembly method of this invention is used for assembling trusses, the laser generated outline may be used to orient the truss planks. 
     U.S. Pat. No. 7,463,368 to Morden et al. titled “LASER PROJECTION SYSTEM, INTELLIGENT DATA CORRECTION SYSTEM AND METHOD” issued Dec. 9, 2008, and is incorporated herein by reference. In U.S. Pat. No. 7,463,368 Morden et al. describe a laser projection system, intelligent data correction system and method which corrects for differences between the as-built condition and the as-designed condition of a workpiece which includes determining the as-built condition of a workpiece with a digitizer scanner and modifying data of the as-built condition or the data of a laser projection based upon the data received from the digitizer scanner of the as-built condition. A preferred intelligent data correction system includes metrology receivers fixed relative to the digitizer scanner and the workpiece and a metrology transmitter to determine the precise location and orientation of the digitizer scanner relative to the workpiece. 
     U.S. Pat. No. 7,621,053 to Edward S. Bianchin titled “ASSEMBLY APPARATUS,” issued Nov. 24, 2009, and is incorporated herein by reference. In U.S. Pat. No. 7,621,053 Bianchin describes an assembly apparatus for assembling components including a work surface, a laser projector, a computer controlling the laser projector to protect a laser image on the work surface, and an ejector lifting a completed assembly from the work surface having a retro-reflective surface within a field of view of the laser projector when the ejector is lifted, such that the laser projector scans the retro-reflective surface and the computer determines at least one of the number of completed assemblies made and the time required to make the assembly. 
     United States Patent Publication 2010/0201702 of Franik et al. published Aug. 12, 2010 with the title “DIGITAL IMAGE PROJECTION LUMINAIRE SYSTEMS,” and is incorporated herein by reference. In Patent Publication 2010/0201702 Franik et al. describe improvements to digital imagine projection systems and for seamless blending of images projected from a plurality of digital image projectors to create combined images from multiple projectors where the user is provided with independent control of the blend area and of independent control of image parameters within said variable blend area such as brightness, contrast, individual color intensity and gamma correction. 
     U.S. Pat. No. 8,079,579 to Fredrickson et al. titled “Automatic truss jig setting system,” issued Dec. 20, 2011, and is incorporated herein by reference. In U.S. Pat. No. 8,079,579 Fredrickson et al. describe an automatic truss jig setting system that includes a table including a plurality of segments with a side edge of adjacent segments defining a slot. At least one pin assembly, and optionally a pair of pin assemblies, is movable independently of each other along the slot. Movement apparatus is provided for independently moving the pin assemblies along the slot. Each of the side edges of the segments associated with the slot defines a substantially vertical plane with a zone being defined between the substantially vertical planes of the side edges, and the movement apparatus is located substantially outside of the zone of the slot. The invention may optionally include a system for handling the obstruction of pin assembly movement, and a system for keeping track of the position of the pin assembly when the pin assembly has encountered an obstruction. 
     U.S. Pat. No. 8,782,878 to Morden et al., titled “FASTENER AUTOMATION SYSTEM,” issued Jul. 22, 2014, and is incorporated herein by reference. In U.S. Pat. No. 8,782,878, Morden et al. describe a fastener automation system for assembly of fasteners to a substrate, which includes a projection system for projecting an image on a substrate of a predetermined location of a correct fastener to be installed in the substrate and data relating to the correct fastener and the substrate, and a computer operably associated with the projection system storing data regarding the correct fastener and the predetermined location on the substrate where the correct fastener is to be installed. An automated method of installing a fastener in a substrate at a predetermined location includes using a projector system to identify a predetermined location for installation of a correct fastener to the substrate, collecting data regarding the correct fastener installation at the predetermined location and storing the data in a computer, and installing the correct fastener in the substrate at the predetermined location based upon the data. 
     United States Patent Publication 2008/0297740 of Huynh et al. published Dec. 4, 2008 with the title “Projection system and method of use thereof,” and is incorporated herein by reference. In Patent Publication 2008/0297740 Huynh et al. describe a projection system and method of use thereof, wherein a computer in electrical communication with at least one projector projects a layout, preferably onto a floor projection surface utilizing short throw lenses, wherein the layout preferably comprises a grid and indicia relating to an exhibitor. 
     U.S. Pat. No. 8,919,001 to Le Mer et al. titled “METHOD AND SYSTEM FOR HELPING TO POSITION A COMPONENT ON A STRUCTURAL ELEMENT,” issued Dec. 30, 2014, and is incorporated herein by reference. In U.S. Pat. No. 8,919,001 Le Mer et al. describe a method for helping to position a component on the wall of a structural element, including the steps: elaborating an image to be projected on the wall, from a virtual model of the structure and from the positioning of a projector with respect to the structure, and an additional motif providing positioning information of the piece with respect to the direction normal to the wall, projecting the image on the structural element by means of the projector; placing the base of the piece inside an outline of the image projected on the wall; and, while keeping contact between the piece and the structural element, modifying the positioning of the piece with respect to the direction normal to the wall, until the predefined set of points of the piece coincides with the motif. 
     U.S. Pat. No. 8,960,244 to Aylsworth et al. titled “AUTOMATED LUMBER RETRIEVAL AND DELIVERY,” issued Feb. 24, 2015, and is incorporated herein by reference. In U.S. Pat. No. 8,960,244 Aylsworth et al. describe an automated lumber handling system that laser-scans the top profile of multiple stacks of lumber, each of which contain boards of a unique size. Based on the scanned profiles, the system determines the order in which individual boards from a chosen stack should be transferred to a numerically controlled saw. The saw cuts the boards to proper size, and in the proper sequence to facilitate orderly assembly of a roof truss or prefabricated wall. In some examples, the system lifts individual boards by driving two retractable screws, or some other piercing tool, down into the upward facing surface of the board. A track mounted cantilever, holding the screws and a laser unit, translates over the lumber stacks to retrieve and deliver individual boards and, while doing so, the laser repeatedly scans the stacked lumber profiles on-the-fly to continuously update the profiles. The open cantilever design facilitates replenishing the stacks of lumber. 
     Chinese Patent Publication CN 202899636 U published Apr. 24, 2013 with the title “Discrete assembly device for large-span rectangular spatially warped tube truss,” and is incorporated herein by reference. This Chinese Patent Publication CN 202899636 describes a discrete assembly device for a large-span rectangular spatially warped tube truss. The device consists of a base, two supporting tubes fixedly connected to the two sides of the base, and tube brackets fixedly connected to the tops of the supporting tubes, wherein grooves of which the diameter is matched with that of a lower chord of an assembly section truss are formed on the tube brackets. The on-site assembly difficulty of the large-span rectangular spatially warped truss is reduced, assembly accuracy and speed are greatly improved, and construction materials are saved. 
     There is a need in the art for better sawing stations and for systems cut two or more boards having various lengths and end-angles from a single piece of stock lumber that may be warped, twisted, and/or crooked, wherein the system shortens the path along which a piece of lumber moves, while performing lumber analysis, sorting, adjustment, and sawing of boards for assembly of a product, such as the assembly of wooden roof trusses, pre-assembled walls, and the like. 
     SUMMARY OF THE INVENTION 
     In some embodiments, the present invention provides a multi-headed sawing station that supports a piece of lumber on a substantially horizontal support bar located at each one of two saw heads, wherein the piece of lumber is also held against two single-point-of-contact substantially vertical fence posts, one associated with each one of the saw heads. In some embodiments, both saw heads move downward simultaneously to simultaneously cut two desired boards from the ends of the piece of lumber. In some embodiments, each saw head then automatically moves toward a center of the piece of lumber, while the board is supported by the horizontal support bar located at each saw head, and the board is also held to prevent slipping as the horizontal support bars move towards one another. In some embodiments, both saw heads again move downward simultaneously to simultaneously cut two more desired boards from the ends of the piece of lumber. In some embodiments, each saw head is independently rotatable around a vertical axis, in order that the ends of the desired cut boards are at a desired angle as well as at a desired length. In some embodiments, each saw head is also independently rotatable around a horizontal axis, in order that the ends of the desired cut boards are at a desired compound angle as well (i.e., angled at both a horizontal angle and a vertical angle). 
     In some embodiments, the present invention also provides a vacuum-activated picker arm that includes a plurality of suction cups that are optionally staggered at one or more distances on either side of a straight line, in order that if one or more of the suction cups fails to achieve a satisfactory grip on a piece of lumber (perhaps due to a crack or other defect in the piece of lumber, others of the plurality of suction cups will achieve enough of a grip to reliably pick up and move the piece of lumber. Some embodiments further include a plurality of compressed-air blowers to remove sawdust or other debris that may be on the piece of lumber, in order to reduce the amount of leakage at the plurality of suction cups. Some embodiments further include a plurality of compressed-air blowers to speed the release of the piece of lumber once it reaches its destination. 
     In some embodiments, the present invention provides a method and associated system that includes a computer processor, wherein the computer processor includes: a plurality of input data devices, a plurality of output data devices, and a plurality of sensors, and wherein the system further includes a mechanical assembly integrated with the computer processor to analyze the geometry of a piece of wood or lumber and, if necessary, reposition the piece and convey the piece to a saw or to a reject station, based on software code executing in the computer processor. Some embodiments organize each incoming stack of lumber in one of a plurality of vertically spaced apart bunks, one on top of another, and provide a gantry that picks a selected board from the stack of lumber on a selected bunk, and moves to board in a direction generally parallel to the long axis of the board from the bunk to one of a plurality of processing stations, wherein the plurality of processing stations includes a flipping station and/or a sawing station. Organizing the lumber bunks in vertical assemblies greatly reduces the footprint of the overall system, thus making more efficient use of valuable factory space and reducing costs. Using the present invention, one can buy lower-grade lumber and sort the boards to obtain suitable and usable pieces for a given end product, thus reducing cost and improving quality of the end product. 
     In some embodiments, the present invention provides a system and associated method that operates on a computer processor having a plurality of input data devices, a plurality of output data devices, a plurality of sensors, a database, software code, and a wireless interface, wherein the computer processor is integrated with mechanical components, and wherein the method includes eliciting and receiving into the computer processor data parameters from a first human user; obtaining incoming data points about lumber from the plurality of sensors (e.g., in some embodiments, from optical point distance sensors and/or three-dimensional (3D) machine-vision systems); processing the data parameters to obtain processed data parameters; storing the processed data parameters; comparing the incoming data points from the plurality of sensors to the stored data parameters to obtain comparison results; and, based on the comparison results, (1) directing the mechanical components to reject the wood to a preprogrammed position, (2) directing the mechanical components to feed the lumber into a saw assembly as positioned, or (3) directing the mechanical components to reposition the lumber to a more optimal position prior to feeding the lumber to a saw assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1A  is a schematic front-perspective-view diagram of a saw system  101  that has a plurality of heads  110  (e.g.,  110 A and  110 B in this figure) that can move left-to-right and can rotate around a vertical axis in order to accurately cut a plurality of relatively short boards having different horizontal cut angles from a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 1B  is a schematic top-view diagram of a saw head  110  that can move left-to-right to one of several positions, and that can rotate around a vertical axis in order to accurately cut a plurality of relatively short boards having different horizontal cut angles from a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 1C  is a schematic side-perspective-view diagram of a saw head  110  that can move left-to-right and can rotate around a vertical axis (and, in some embodiments, also around a horizontal axis) in order to accurately cut a plurality of relatively short boards having different horizontal- or compound-cut angles from a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 1D  is a schematic front-perspective-view diagram of a saw head  110  (e.g., which could be used for  110 A and/or  110 B) that can move left-to-right and can rotate around a vertical axis in order to accurately cut a plurality of relatively short boards having different horizontal cut angles from a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 1E  is a schematic front-perspective-view diagram of portions of saw system  101  that has a plurality of heads  110  (e.g.,  110 A and  110 B in this figure) that each can move left-to-right and can rotate around a vertical axis and/or a horizontal axis in order to accurately cut a plurality of relatively short boards having different horizontal- or compound-cut angles from a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 1F  is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1A  a short time after that shown in  FIG. 1A , i.e., just after two boards have been cut from piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 1G  is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1F  a short time after that shown in  FIG. 1F , i.e., just after rotating head  110 A for the next cut, according to some embodiments of the present invention. 
         FIG. 1H  is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1G  a short time after that shown in  FIG. 1G , i.e., just after cutting an angled piece using rotated head  110 A, and possibly moving head  110 B for the next cut, according to some embodiments of the present invention. 
         FIG. 1 i    is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1H  a short time after that shown in  FIG. 1H , i.e., just after moving head  110 A and head  110 B for the next cut, according to some embodiments of the present invention. 
         FIG. 1J  is a schematic front-perspective-view diagram of saw system  101  of FIG.  1   i  a short time after that shown in  FIG. 1 i   , i.e., just after two more boards have been cut from piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 2A  is a schematic diagram  201  showing exemplary data points used to detect crook in a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 2B  is a schematic diagram  202  showing exemplary data points used to detect bow in a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 2C  is a schematic diagram  203  showing exemplary data points used to detect twist in a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 2D  is a schematic diagram  204  showing exemplary data points used to detect wane  240  and cracks  241  in a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 2E  is a schematic diagram  205  showing exemplary data points used to detect a knot  250  in a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 2F  is a schematic diagram  206  showing exemplary data points used to detect cupping  251  in a piece of lumber  99 , according to some embodiments of the present invention. 
         FIG. 3A  is a side-view schematic diagram of a multi-station lumber-cutting system  302  that includes a plurality of lumber-transfer-and-cutting systems  301 A,  301 B, according to some embodiments of the present invention. 
         FIG. 3B  is an end-view schematic diagram of multi-station lumber-cutting system  302 , according to some embodiments of the present invention. 
         FIG. 3C  is a flowchart of a method  303 , according to some embodiments of the present invention. 
         FIG. 3D  is a diagram of a portion of a stack of trusses  304  that have uneven butt-end heights, which often results from conventional saw equipment. 
         FIG. 3E  is a diagram of a portion of a stack of trusses  305  that have even uniform butt-end heights, as a result of the more accurate end cut achievable from saw system  101  of the present invention. 
         FIG. 4  is a side-view block diagram of a lumber-cutting system  401  that includes one or more lumber-transfer systems  410 A,  410 B, and a stacked-shelf lumber store  420 , according to some embodiments of the present invention. 
         FIG. 5A  is a perspective-view block diagram of a lumber-cutting system  501 , according to some embodiments of the present invention. 
         FIG. 5B  is a perspective-view block diagram of a lumber-cutting system  502 , according to some embodiments of the present invention. 
     
    
    
     COPYRIGHT NOTICE/PERMISSION 
     A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. The following notice applies to the software and data as described herein and in the drawings hereto in the attached appendices: Copyright © 2014-2017, Steven R. Weinschenk, All Rights Reserved. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Although the following detailed description contains many specifics for the purpose of illustration, a person of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Specific examples are used to illustrate particular embodiments; however, the invention described in the claims is not intended to be limited to only these examples, but rather includes the full scope of the attached claims. Accordingly, the following preferred embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon the claimed invention. Further, in the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. 
     It is specifically contemplated that the present invention includes embodiments having combinations and subcombinations of the various embodiments and features that are individually described herein (i.e., rather than listing every combinatorial of the elements, this specification includes descriptions of representative embodiments and contemplates embodiments that include some of the features from one embodiment combined with some of the features of another embodiment, including embodiments that include some of the features from one embodiment combined with some of the features of embodiments described in the patents and application publications incorporated by reference in the present application). Further, some embodiments include fewer than all the components described as part of any one of the embodiments described herein. 
     The leading digit(s) of reference numbers appearing in the Figures generally corresponds to the Figure number in which that component is first introduced, such that the same reference number is used throughout to refer to an identical component which appears in multiple Figures. Signals and connections may be referred to by the same reference number or label, and the actual meaning will be clear from its use in the context of the description. 
     Certain marks referenced herein may be common-law or registered trademarks of third parties affiliated or unaffiliated with the applicant or the assignee. Use of these marks is for providing an enabling disclosure by way of example and shall not be construed to limit the scope of the claimed subject matter to material associated with such marks. 
     As used herein, “crook” is a lumber feature or defect where the widest faces of the piece of lumber are substantially planar but there is a curvature along the length of the narrower faces of the piece of lumber. The “crown” is the convex one of the narrower faces of the piece of lumber with a crook. See  FIG. 2A . 
     As used herein, “bow” is a lumber feature or defect where the narrower faces of the piece of lumber are substantially planar but there is a curvature along the length of the wider faces of the piece of lumber. See  FIG. 2B . 
     As used herein, “twist” is a lumber feature or defect in which there are curvatures across multiple surfaces in the lumber. See  FIG. 2C . 
     As used herein, “wane” is a lumber feature or defect that is characterized by bark or insufficient wood at a corner or along an edge, due to the piece of lumber being cut from an outer edge of the log. See  FIG. 2D . 
     As used herein, “knot” is a lumber feature or defect that is characterized by a separated branch piece or hole in a piece of lumber. See  FIG. 2E . 
     As used herein, “cup” is a lumber feature or defect where there is a curvature across the width of the widest face of the lumber, in which the edges are higher or lower than the center of the piece of lumber. See  FIG. 2F . 
       FIG. 1A  is a schematic front-perspective-view diagram of a saw system  101  that has a plurality of saw-head assemblies  110  (e.g.,  110 A and  110 B in this figure) that can move left-to-right and can rotate around a vertical axis in order to accurately cut a plurality of relatively short boards having different horizontal cut angles from a piece of lumber  99 , according to some embodiments of the present invention. In some embodiments, saw system  101  includes a support stand  191 - 192  that extend upward from base  193 . In some embodiments, the support stand  191 - 192  holds one or more horizontal support rails  190  upon which the plurality of saw heads  110  move. In some embodiments, a grip actuator  194  is configured to move gripper arm  195  to press against board  99  at location  196  to urge board  99  downward against board-support arms  118  of each saw head  110 A and  110 B, and inward against locations  197  and  198 . In some embodiments, gripper arm  195  reaches over board  99 , lowers its curved (e.g., hook-shaped) distal end around board  99  and then pulls board  99  down and in against fence-post rod  117  and board-support arm  118  (also called a support rod  118 ) of both saw-head assemblies  110 A and  110 B. In some embodiments, gripper arm  195  includes two jaws that clamp two opposite faces (top and bottom or far and near sides) of board  99 . In some embodiments, a plurality of grip actuators  194  and gripper arms  195  are provided (e.g., in some embodiments, one set of gripper arm-actuators on each saw-head assembly  110 A and  110 B). In some embodiments, board-support arms  118  and/or “fence post” rods  117  are each cylindrical (e.g., see  FIG. 1B ) in order to provide stable contact points and minimize possible rocking motion of warped or twisted boards. In other embodiments, board-support arms  118  and/or “fence post” rods  117  are each rectangular, triangular or other suitable shapes as needed to suit the requirements of boards having possible board defects (i.e., boards that are not perfectly straight and rectangular). The substantially three-point contact arrangement  196 - 197 - 198  accommodates twisted or warped or crooked boards while minimizing the rocking that commonly occurs when holding a convexly curved board against a conventional straight-wall saw fence. This allows more accurate cuts and can improve safety by not having the workpiece shift part-way through a cut (which can cause a piece of board to fly out at high speed). The dash-dot outline  91  represents a hypothetical straight board that is otherwise similar to actual board  99 , which is shown in solid lines. In some embodiments, each saw-head assembly  110 A and  110 B includes a saw blade  111  that is rotated by motor  113  (and/or moved in a direction parallel to a line above board-support arm  118  toward and away from “fence post” rod  117  by a linear actuator coupled to and associated with motor  113 ), which is raised and lowered by up-down actuator  112 , that is attached to support beam  115 . In some embodiments, support beam  115  is attached to two linear actuators  114  that move the respective saw-head assembly  110 A and  110 B leftward and rightward along the one or more horizontal support rails  190 . In some embodiments, rotation actuator  116  rotates cylindrical “fence post” rod  117 , which holds bottom board-support arm  118  and upper support arm  128 , around its longitudinal axis (which is substantially vertical in this embodiment). Being cylindrical, rod  117  provides a single back support point  197  or  198  against which board  99  rests regardless of the amount of angular rotation actuator  116  provides around the vertical rotation axis. In some embodiments, board-support arm  118  is also cylindrical so that rotation around a horizontal axis also presents a constant vertical distance of the board from the horizontal longitudinal axis of board-support arm  118 . In some embodiments, board support arm  118  and upper support arm  128  are cantilevered from “fence post” rod  117  near its lower and upper ends, respectively. In some embodiments, upper support arm  128  provides an anchor position for up-down actuator  112  which is connected to motor  113 , such that when angular rotation actuator  116  rotates “fence post” rod  117 , the entire saw portion  111 ,  112 ,  113 ,  118  and  128  all rotate together to the same angle as “fence post” rod  117 , such that saw blade  111  always cuts off the severed end of board  99  right next to, and parallel to, board support arm  118 . This provides excellent height control of the butt end of angled principal rafters of roof trusses, even when the source board  99  is somewhat crooked, twisted or warped. Thus, the present invention provides cut boards that have the correct desired lengths and cut angles (which are particularly important for even though the middle of the board is warped. 
       FIG. 1B  is a schematic top-view diagram of a saw head  110  (shown here in three different positions and orientations) that can move left-to-right to one of several positions, and that can rotate around a vertical axis in order to accurately cut a plurality of relatively short boards having different horizontal cut angles from a piece of lumber  99 , according to some embodiments of the present invention.  FIG. 1B  shows the same saw head  110  in three different horizontally displaced positions along top rails  190 . In some embodiments, horizontal linear actuators  114  are used to move saw head  110  to the desired horizontally displaced position, while rotary actuator  116  is used to rotate saw head  110  to the desired angle relative to the longitudinal axis of board  99  (e.g., to cut the ends of primary rafters to the desired angle). 
       FIG. 1C  is a schematic side-perspective-view diagram of a saw head  110  that moves left-to-right (using linear actuators  114 ), that rotates around a vertical axis (using rotary actuator  116 ), and, in some embodiments, that also rotates around a horizontal axis (using rotary actuator  136 ) in order to accurately cut a plurality of relatively short boards having different horizontal- or compound-cut angles from a source piece of lumber  99 , according to some embodiments of the present invention. Due to the entire saw portion  111 ,  112 ,  113 ,  118  and  128  of saw head  110  all rotating together to the same angle as “fence post” rod  117   
       FIG. 1D  is a schematic front-perspective-view diagram of a saw head  110  (e.g., which could be used for  110 A and/or  110 B) that can move left-to-right and can rotate around a vertical axis in order to accurately cut a plurality of relatively short boards having different horizontal cut angles from a piece of lumber  99 , according to some embodiments of the present invention. 
       FIG. 1E  is a schematic front-perspective-view diagram of portions of saw system  101  that has a plurality of heads  110  (e.g.,  110 A and  110 B in this  FIG. 1E ) that each can move left-to-right (using linear actuators  114  to change the length of the board being cut) and can rotate around a vertical axis (using rotary actuator  116  to change the horizontal angle of the board being cut) and/or a horizontal axis (using rotary actuator  136  to change the vertical angle of the board being cut) in order to accurately cut a plurality of relatively short boards having different horizontal-angle (such as saw head  110 A shown here cutting at a non-perpendicular horizontal angle relative to the length of board  99 ), vertical-angle (such as saw head  110 B shown here cutting at a non-perpendicular vertical angle relative to the length of board  99 ) or compound-cut angles from a piece of lumber  99  (i.e., such as a saw head  110 A or  110 B cutting at both a non-perpendicular vertical angle and non-perpendicular horizontal angle relative to the length of board  99 , not shown here but obvious to one of skill in the art, wherein both rotary actuator  116  and rotary actuator  136  rotate to set the saw blade to cut a compound-angle cut), according to some embodiments of the present invention. 
       FIG. 1F  is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1A  a short time after that shown in  FIG. 1A , i.e., just after two boards,  88  and  89 , each having an end cut perpendicular to their long axes, have been cut from piece of lumber  99 , according to some embodiments of the present invention. 
       FIG. 1G  is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1F  a short time after that shown in  FIG. 1F , i.e., just after rotating head  110 A for the next angled cut, according to some embodiments of the present invention. 
       FIG. 1H  is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1G  a short time after that shown in  FIG. 1G , i.e., just after cutting an angled piece  87  using rotated head  110 A, and possibly moving head  110 B for the next cut, according to some embodiments of the present invention. 
       FIG. 1 i    is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1H  a short time after that shown in  FIG. 1H , i.e., just after moving head  110 A and head  110 B for the next two cuts, according to some embodiments of the present invention. 
       FIG. 1J  is a schematic front-perspective-view diagram of saw system  101  of  FIG. 1 i    a short time after that shown in  FIG. 1 i   , i.e., just after two more boards,  85 , having an angled end cut, and  86 , having an end cut perpendicular to its long axes, have been cut from piece of lumber  99 , according to some embodiments of the present invention. 
       FIG. 2A  is a schematic diagram  201  showing a top view of a plurality of exemplary data points  291  that, in some embodiments, are gathered along the length of a board and used to detect crook in a piece of lumber  99 , and if crook is detected, used to determine the crown face  91  and the amount of curve on the crown face  91 , according to some embodiments of the present invention. 
       FIG. 2B  is a schematic diagram  202  showing a side view of a plurality of exemplary data points  292  that, in some embodiments, are gathered along the length of a board and used to detect bow in a piece of lumber  99 , and if bow is detected, used to determine the amount and direction of curve on the bowed face  92 , according to some embodiments of the present invention. 
       FIG. 2C  is a schematic diagram  203  showing a side view of a plurality of exemplary data points  293  that, in some embodiments, are gathered along the length of a board and used to detect twist in a piece of lumber  99 , and if twist is detected, used to determine the amount and direction of curve on the twisted face  93 , according to some embodiments of the present invention. 
       FIG. 2D  is a schematic diagram  204  showing a perspective view of a plurality of exemplary data points  294  that, in some embodiments, are gathered across the width of a board and used to detect cracks  241  and wane  240  in a piece of lumber  99 , and if cracks and/or wane are detected, used to determine the amount and position of any crack(s) and/or the amount and which corner(s) are missing on the wane surface  94 , according to some embodiments of the present invention. 
       FIG. 2E  is a schematic diagram  205  showing a perspective view of a plurality of exemplary data points  295  that, in some embodiments, are gathered across the width of a board and used to detect a knot  250  in a piece of lumber  99 , and if one or more knots are detected, used to determine the size and position of any knots and/or the amount (size) and positions of the missing wood at the knot position  95 , according to some embodiments of the present invention. In some embodiments, one or more of the data points (e.g., point  295 ′) indicates a data point in the middle of a board that is well below the other data points  295  on the top surface. 
       FIG. 2F  is a schematic diagram  206  showing a perspective view of a plurality of exemplary data points  296  that, in some embodiments, are gathered across the width of a board and used to detect cupping  251  in a piece of lumber  99 , and if cupping is detected, used to determine the amount and direction of curve/cupping on the cupped face  96 , according to some embodiments of the present invention. 
       FIG. 3A  is a side-view schematic diagram of a multi-station lumber-cutting system  302  that includes a plurality of dual-saw lumber-picking-and-cutting systems  301 A,  301 B, according to some embodiments of the present invention. In some embodiments, system  302  includes one or more saw systems  101  (e.g., in some embodiments, saw system  101 A and saw system  101 B; each embodying a saw system  101  as shown in  FIG. 1A ). In some embodiments, system  302  includes one or more computer processors  305  (in some embodiments, a Raspberry Pi® is used for processor  305  and is located on mechanical-assembly gantry  308 , and uses open-source software (e.g., such as OPENCV) that has box, line, and color detection as well as knot and crack detection, where sometimes wane shows better in in images from a visual sensor due to the color of bark), wherein computer processor  305  includes a plurality of input/output data devices  306  and a plurality of gantry sensors  307  that obtain image, angle and/or distance data  377  from the top and/or side of one or more pieces of lumber  99  on cart  320 , and/or bottom-side sensors (not shown here) that obtain image and/or distance data from the bottom of a piece of lumber  99  that has been removed from a cart  320  (e.g., in some embodiments, one of a plurality of such carts  320 ) as the piece of lumber is being moved toward the optional rejection station sensors (not shown here), the optional flip station sensors (not shown here) and/or one or more saw stations  390  (in some embodiments, each embodying a saw system  101 ; also see  FIG. 3B ). In some embodiments, each dual-saw lumber-picking-and-cutting systems  301 A,  301 B of system  302  further includes a mechanical assembly  308  on a gantry and integrated with computer processor  305  to grab (using picker assembly  325 ; e.g., such as described in co-pending U.S. patent application Ser. No. 15/426,966, filed Feb. 7, 2016, titled “AUTOMATED SYSTEM AND METHOD FOR LUMBER PICKING,” which is incorporated herein by reference) and reposition a piece of wood lumber  99  based on software code executing in computer processor  305  that processes the point location data received from gantry sensors  307  and/or bottom-side sensors  307 ′. In some embodiments, a database  330  (containing criteria-and-action data for each one of a plurality of end products to be made from the lumber) is operatively coupled to computer processor  305 . In some embodiments, a non-transitory computer-readable medium  310  (storing thereon instructions for performing the method of the present invention) is connectable to computer processor  305 , for example, via one or more of the plurality of input/output data devices  306 . While multi-station lumber-cutting system  302  is shown as including duplicate versions of certain units (such as database  340 ), other embodiments share single copies of various units among the plurality of dual-saw lumber-picking-and-cutting systems  301 A,  301 B shown here. Some embodiments use a single dual-saw lumber-picking-and-cutting system  301 A, while other embodiments use more than two. Other embodiments use a single set of one or more carts  320  that are centrally located and position the saw systems  101 A and  101 B on opposite sides of the centrally located set of cart(s)  320 . 
       FIG. 3B  is an end-view schematic diagram of lumber-cutting system  302 , according to some embodiments of the present invention, which, for convenience, illustrates the processing of lumber where the lumber is moved left-to-right for the dual-saw lumber-picking-and-cutting system  301 A and right-to-left for the dual-saw lumber-picking-and-cutting systems  301 B in the  FIG. 3B . In some embodiments, only top-side gantry-located sensors  307  are used, while in other embodiments, only bottom-side sensors  307 ′ are used, while in yet other embodiments, both top-side gantry sensors  307  and bottom-side sensors  307 ′ are used. In some embodiments, the mechanical assembly (e.g., the gantry)  308  has (in addition to the gantry sensors  307  if used) a single board-picker mechanism  325  that is used and carries one board at a time (from left-to-right in the  FIG. 3B ), while in other embodiments, gantry  308  has (in addition to the gantry sensors  307  if used) a plurality of board-picker mechanisms  324 - 325  that are each used to carry one or more boards at a time (from left-to-right in the  FIG. 3B ). In some embodiments, each of the plurality of board-picker mechanisms  324 - 325  uses staggered suction cups as described in co-pending U.S. patent application Ser. No. 15/426,966, filed Feb. 7, 2017 by Steven Weinschenk, titled “AUTOMATED SYSTEM AND METHOD FOR LUMBER PICKING,” which is incorporated herein by reference. In some embodiments, gantry  308  is operable to pick one or more boards from each of one or more of a plurality of carts  320 - 321  (only two of which are shown here). 
     Continuing to refer to  FIG. 3B , in some embodiments that use only top-side gantry-located sensors  307 , a board  99  is scanned or imaged by gantry sensors  307  to determine the position and orientation of board  99  in absolute terms and/or in relation to other boards  97  and  98 . In some embodiments, the points along the edges and top surface of board  99  are determined and distinguished by the height difference relative to the points detected of a lower board  97 . In some embodiments, the points along the edges and top surface of board  99  are determined and distinguished by the brightness differences of the boards relative to the spaces between top board  99  and top board  98 . In some embodiments, the points along the edges and top surface of board  99  obtained from top-side gantry-located sensors  307  are used to position picker(s)  324  and/or  325  in order to pick up board  99  (and/or simultaneously pick up board  98 ). Based on the geometry data obtained from the top-side gantry-located sensors  307 , the board  99  is picked up by path  371 , carried along path  372 , possible dropped along path  379  to a rejection pile (in the case where system  302  and method  303  have determined that the current processing stations are not able to accommodate the detected flaws in the board), or deposited on flip station  378  by path  373  and/or taken to saw station  390  by path  375 . In some embodiments, if the board is deposited on flip station  378 , it is flipped over along path  374  (rotated 180 degrees around its long axis) and then the opposite side is inspected by gantry sensors  307  (or the board is picked up by picker(s)  324 - 325  and transported back over the bottom-side sensors  307 ′ (only one set of possibly more than one are shown here) to perform the detailed inspection of the side not originally inspected during the first pass over sensors  307 ′), and based on the inspection of the opposite side, the now doubly-inspected board is dumped at the reject pile or transported and placed on saw station  390 . In some embodiments, a conveyor  392  receives the cut boards (e.g., dropped via paths  391 ) and conveys the cut boards via path  393  to a truss-assembly table such as described in U.S. patent application Ser. No. 15/093,732 by Steven R. Weinschenk et al., titled “DIGITAL PROJECTION SYSTEM AND METHOD FOR WORKPIECE ASSEMBLY” which is incorporated herein by reference. 
       FIG. 3C  is a flowchart of a method  303 , according to some embodiments of the present invention. In some embodiments of method  303 , at block  341 , the system (e.g., system  302  of  FIG. 3A  and  FIG. 3B ) gathers data from sensors as to dimensions, geometry (curvature), color and/or other attributes regarding a piece of available lumber (e.g., of a particular board  99 ). In some embodiments, at block  342 , the system  302  elicits acceptable lumber data from a user  90  and/or from a stored set of data from database  340  that correlates characteristics of lumber with certain actions to be taken by the system, based on the end product to be built using the pieces of lumber. In some embodiments, system  302 , using method  303 , elicits and receives, from a human user  90  using one or more input/output devices  320 , selection data that the system  302  uses to selects one or more sets of criteria and corresponding actions from a stored database that has been pre-loaded with a plurality of sets of criteria and corresponding actions that have been predetermined to meet requirements for each of a plurality of possible end products to be built using the pieces of lumber. 
     In some embodiments, the present invention utilizes one or more of the user devices  320  of each user  90 , such as a desktop personal computer  361 , laptop computer  362 , tablet computer  363 , smartphone  364 , a position-sensing device  365  (which in some embodiments, is a stand-alone Global Positioning System (GPS) device (such as made by Garmin Ltd.) or in other embodiments, is part of a position-tracking system or another device such as a smartphone  364  or the like), and/or other devices such as wearable computers in clothing or smartwatches  367  or the like. 
     In some embodiments, the human user  90  or database  340  responds to the eliciting of information by indicating to system  302  which one of a plurality possible end-products is to be manufactured, wherein the criteria and actions for each respective end product is customized and optimized for that respective end product and stored in database  130 , such that when an indication is received from the device  360  of user  90 , that set of data is then used for the operations of blocks  343  through  349 . In some embodiments, at block  341 , sensors gather physical data from lumber. In some embodiments, distance data is received from each of one or more sensors for each of a plurality of point locations on one or more pieces of lumber. In some embodiments, those distance data are processed to obtain XYZ coordinates for each of the plurality of point locations, and curve-fitting algorithms are applied to find edges and surfaces of the one or more pieces of lumber, and determine the shapes and curves of edges and surfaces of the lumber. In some embodiments, at block  343 , the physical geometric data is compared to the selected set of lumber parameters to obtain data comparison results. In some embodiments, at block  344 , the data comparison results have been determined to be acceptable and therefore the piece of lumber is delivered to the saw station  390  where it is cut into boards having the desired lengths and end-angles for the end product being manufactured (such as, for example, a truss). 
     In some embodiments, at block  345 , the data comparison results have been determined to be unacceptable. If the board is un-fixable (at least in regards to this particular station and the uses to which the lumber is to be applied in a commercially reasonable fashion), control is passed to block  348 , and the piece of lumber is delivered to the rejection area. In some embodiments, at block  346 , the piece of lumber is determined to be processable if reoriented, so that piece should be reoriented, so as a result the lumber is delivered to a reorienter. In some embodiments, at box  347 , the orientation of the lumber is changed by the reorienter and then the now-reoriented piece of lumber is delivered to the processing equipment—so control passes to block  343  where data on the reoriented board is again compared to the requirements of the truss parts being cut. 
     In some embodiments, system  302  uses its detection of the crown face (which typically has only one “high” point) of a crooked board to place the side opposite the crown face (which typically has two “high” points) against the saw fence of saw station so the board is more stable and does not move as the board is being sawed. Flip station  378  facilitates this positioning. 
     In some embodiments, system  302  uses method  303  (See  FIG. 3C ) to elicit and receive optical and/or XYZ point locations data (geometry data regarding the surfaces and edges of the lumber) to detect and measure wane or cracks on the board (see  FIG. 2D ). In some embodiments, system  301  detects cup defects (see  FIG. 2F ). In some embodiments, the system  302  detects crook defects (see  FIG. 2A ) and determines the crown face of the board. In some embodiments, system  302  further performs wane detection and/or split detection (see  FIG. 2D ), knot detection (see  FIG. 2E ), and/or bark detection (see  FIG. 2D ). 
     In some embodiments, system  302  detects other data (non-geometry data) such as grain quality and ring density. In some embodiments, these parameters are determined by one or more video cameras and one or more machine-vision algorithms applied to images obtained from the camera(s). 
     In some embodiments, system  302  reorients the lumber by physically flipping the lumber piece around its longest axes and/or rotating the lumber piece on one of its short axes to better optimize wood via mechanical action. In some embodiments, reorientation of the lumber is accomplished using compressed air; for example, by placing the piece of lumber on a surface (of flip station  378  of  FIG. 3B ) having a plurality of holes through which compressed air is selectively applied in a short burst along one edge to flip the board around its longest axis. In some other embodiments, reorientation of the lumber uses mechanical clamps or fasteners, such as a clamping device that grabs opposite faces of the piece of lumber, or a piercing device that screws or pierces to grab the lumber and flip the board around its longest axis. 
     In some embodiments, the method  303  and system  302 , determine which ones (of a plurality of boards needed for one or more trusses being assembled on a neighboring truss assembly station) can be cut from the current board  99  on a saw station  390 , and does cuts from one or both ends simultaneously. In some embodiments, it is the end boards that are cut off (e.g., boards  85 ,  86 ,  88 ,  89  of  FIG. 1J )) and that drop to the conveyor that are the truss-member boards that are to be used (or that become unused scraps such as piece  87  of  FIG. 1J ), while the board  99  that remains on the support arms  118  is still raw stock that is yet to be cut to the final desired piece(s). In situations where one saw head  110  is first-arrived to be in position (for the desired length and angle) for a cut but the other saw head is still moving to its desired position, the earlier arriving saw head  110  will make its cut of its truss-member board (e.g., board  85  of  FIG. 1J ) and begin moving to position for the next cut, and when the latter-arriving saw head  110  later reaches its position (length and angle) for cutting the truss-member board from the opposite end of the source board  99 , it will cut its opposite-end truss-member board (e.g., board  86  of  FIG. 1J ). 
       FIG. 3D  is a diagram of a portion of a stack of trusses  304 , each having truss plates  396 , that have uneven butt-end heights  394 , which often results from conventional saw equipment. 
       FIG. 3E  is a diagram of a portion of a stack of trusses  305  that have even uniform butt-end heights  395 , as a result of the more accurate end cut achievable from saw system  101  of the present invention, which can move left-to-right and can rotate around a vertical axis defined by fence post rod  117  and support arm  118 , in order to accurately cut a plurality of relatively short boards having a selected one of a plurality of different possible horizontal and/or vertical cut angles from a piece of lumber  99 , according to some embodiments of the present invention. 
       FIG. 4  is a side-view block diagram of a lumber-cutting system  401  that includes one or more lumber-transfer systems  410 A,  410 B, and a stacked-shelf lumber store  420 , according to some embodiments of the present invention. In some embodiments, system  401  includes a plurality of lumber-transfer systems  410 A,  410 B, each running along a gantry track  419  between stacked-shelf lumber store  420  (e.g., in some embodiments, including a plurality of cantilevered board storage units  428  having shelves or arms that hold a stack of boards  99 , In some embodiments, lumber-transfer systems  410 A,  410 B, each include an extendable column  411  having one or more extensions  415  that allow up-down movement control of swing arms  412  that allow picker head  413  (e.g., in some embodiments, having a plurality of controllable suction cups  414 ) to swing left into a cantilevered board storage unit  428  (above one shelf and below the one next higher) to pick up a board  99 , then move rightward and swing to the right to place the board into saw system  101  (above board-support arms  118  and below the gantry tracks  190 —see  FIG. 1A ) 
       FIG. 5A  is a perspective-view block diagram of a lumber-cutting system  501 , according to some embodiments of the present invention. In some embodiments, system  501  includes a gantry  508  that moves in and out relative to a plurality of stacks of lumber, each located on one of a plurality of bunks  528  (in the embodiment shown here, each bunk uses a shelf  529  to support its stack of lumber; in other embodiments, a plurality of cantilevered arms extending perpendicular to the long axes of the boards are spaced apart along the length of the boards and facilitate loading the bunks using a forklift or similar machinery). that are vertically displaced relative to one another. In some such embodiments, the picker  524  moves left-and-right relative to the figure to reach in above a selected one of the plurality of stacks of lumber  520 - 521 , where one or more stacks of lumber  520 - 521  are placed on a plurality of vertically displaced shelves  529 . A Y-track  537  is used to move the gantry  508  vertically to a selected one of the plurality of shelves  529  and its stack(s) of lumber  520 - 521 , where a picker  524  (e.g., in some embodiments, using suction grippers) picks up a board that has been measured (as described above, for crook, bow, twist, cup, cracks and/or knots and the like), and delivered to saw system  390  and/or flipper  380  (e.g., in some embodiments, located vertically above saw system  390 ), or to the reject station (not shown). Thus, in some embodiments, gantry  508  moves up-down to one of plurality of stacked bunks (using shelves  529  or other suitable supports) of lumber stacks  520 - 521 . Gantry  508  moves left-right over selected stack (e.g.,  521 ) of lumber, picks a selected board  99 , and camera/scanner  507  measures crown, bow, twist, wane, color, grade. Gantry  508  moves back-forth using tracks  538  and  539  between the stacked bunks  528  and saw input table of saw unit  390  (or flipper  380  or the discard pile of the reject unit). 
       FIG. 5B  is a schematic diagram of a lumber-cutting system  502 , according to some embodiments of the present invention. In some embodiments, system  502  is similar to system  501  described above, but has sets of bunks of lumber that are vertically displaced on both of the two sides of a centrally positioned gantry-movement system. Thus, in some embodiments, each lumber-transfer systems  410 A,  410 B moves up-down to one of plurality of stacked bunks (using shelves  529  or other suitable supports) of lumber stacks  520 - 521 . Each lumber-transfer systems  410 A,  410 B moves left-right over selected stack (e.g.,  521 ) of lumber, on the LEFT SIDE OR RIGHT SIDE of the central gantry-movement system  520 , and picks a selected board  99 , and camera/scanner  507  measures crown, bow, twist, wane, color, grade. Each lumber-transfer systems  410 A,  410 B moves back-forth between the two sets of stacked bunks and the selected saw input table of saw unit  101 A or  101 B (or a flipper  380  such as shown in  FIG. 5A  or the discard pile of the reject unit). 
     In some embodiments, the present invention provides an apparatus for sawing a first piece of lumber stock. This apparatus includes a first gantry structure having a length; a first plurality of saw heads including a first saw head having a blade and a second saw head having a blade; a first plurality of lumber supports including a first lumber support and a second lumber support, wherein the first lumber support and the second lumber support are configured to support the first piece of lumber stock; a plurality of actuators operably connected to the first gantry structure and to the first plurality of saw heads, and operably configured to move each one of the first plurality of saw heads and each one of the first plurality of lumber supports to a selected position of a plurality of positions along at least a portion of the length of the first gantry structure; and a saw controller operably connected to the plurality of actuators, and configured during a first period of time to move the first and second saw heads and the first and second lumber supports relative to the first piece of lumber stock as the first and second lumber supports support the first piece of lumber stock such that the first saw head and the first lumber support are located adjacent a first location along the first piece of lumber and the second saw head and the second lumber support are located adjacent a second location along the first piece of lumber, wherein the saw controller operates the first saw head to cut a first board off the first piece of lumber stock at the first location and the saw controller operates the second saw head to cut a second board off the first piece of lumber stock at the second location. 
     In some embodiments, the saw controller is configured during a second period of time to move the first and second saw heads and the first and second lumber supports relative to the first piece of lumber as the first and second lumber supports support the first piece of lumber such that the first saw head and the first lumber support are located at a third location along the first piece of lumber and the second saw head and the second lumber support are located at a fourth location along the first piece of lumber, wherein the saw controller operates the first saw head to cut a third board off the first piece of lumber stock and the saw controller operates the second saw head to cut a fourth board off the first piece of lumber stock. 
     In some embodiments, the first saw head and the first lumber support move together along the first gantry structure at a fixed spatial relationship to one another, and the second saw head and the second lumber support move together along the first gantry structure at a fixed spatial relationship to one another. 
     In some embodiments, the first saw head and the first lumber support move together along the first gantry structure at a fixed spatial relationship to one another and are configured to cut the first board off the first piece of lumber stock such that the blade of the first saw head cuts adjacent and parallel to a length of the first lumber support and such that the first lumber support continues to support the first piece of lumber stock that remains after the first board is cut off, and the second saw head and the second lumber support move together along the first gantry structure at a fixed spatial relationship to one another and are configured to cut the second board off the first piece of lumber stock such that the blade of the second saw head cuts adjacent and parallel to a length of the second lumber support and such that the second lumber support continues to support the first piece of lumber stock that remains after the second board is cut off. 
     In some embodiments, the first saw head and the first lumber support rotate together around a first vertical axis and move together along the first gantry structure at a fixed spatial relationship to one another and are configured to cut the first board off the first piece of lumber stock such that the blade of the first saw head cuts adjacent and parallel to a length of the first lumber support and such that the first lumber support continues to support the first piece of lumber stock that remains after the first board is cut off, and the second saw head and the second lumber support rotate together around a second vertical axis and move together along the first gantry structure at a fixed spatial relationship to one another and are configured to cut the second board off the first piece of lumber stock such that the blade of the second saw head cuts adjacent and parallel to a length of the second lumber support and such that the second lumber support continues to support the first piece of lumber stock that remains after the second board is cut off. 
     Some embodiments further include a first rotary actuator and a second rotary actuator operably connected to the saw controller; a first saw-fence post and a second saw-fence post, wherein the first saw head and the first lumber support are both connected to the first saw-fence post and the first rotary actuator is configured, under control of the saw controller, to rotate the first saw head and the first lumber support together around a vertical axis of the first saw-fence post, and wherein the second saw head and the second lumber support are both connected to the second saw-fence post and the second rotary actuator is configured, under control of the saw controller, to rotate the second saw head and the second lumber support together around a vertical axis of the second saw-fence post; and a board clamp operably connected to the saw controller and configured, under control of the saw controller, to urge the first piece of lumber stock against the first saw-fence post and the second saw-fence post while the first saw head cuts off the first board and the second saw head cuts off the second board. 
     Some embodiments further include a lumber pickup arm operatively coupled to the saw controller and configured to successively pick up at least one of a plurality of pieces of lumber stock from at least one source pile of pieces of lumber stock and to move the at least one piece of lumber stock in a direction substantially perpendicular to a long axis of the at least one piece of lumber stock and to deposit the at least one piece of lumber stock onto the first and second lumber support such that the board clamp can urge the at least one piece of lumber stock against the first saw-fence post and the second saw-fence post. 
     Some embodiments further include a lumber pickup arm operatively coupled to a raise/lower actuator of a second gantry structure, wherein the lumber pickup arm includes a first plurality of selectively air-pressure-activatable suction cups arranged in a staggered configuration; a first plurality of air valves operably connected to the first plurality of suction cups; an optical location device configured to generate location parameters for where the first piece of lumber is to be picked up; and a pickup controller operably connected to the first plurality of air valves and configured to control the raise/lower actuator to lower the lumber pickup arm based on the location parameters of where the first piece of lumber is to be picked up so that a first sub-plurality of the first plurality of suction cups seat on the first surface of the first piece of lumber, and to operate the first plurality of air valves so as to reduce air pressure in the first sub-plurality of the first plurality of suction cups to grab the first piece of lumber, wherein the pickup controller later increases air pressure in the plurality of the first plurality of suction cups to release the first piece of lumber. 
     In some embodiments, the present invention provides a method for sawing a first piece of lumber stock. This method includes: providing a first gantry structure having a length, a first plurality of saw heads supported by the first gantry structure including a first saw head having a blade and a second saw head having a blade, and a first plurality of lumber supports including a first lumber support and a second lumber support; supporting the first piece of lumber stock on the first lumber support and the second lumber support; moving, during a first period of time, the first and second saw heads and the first and second lumber supports relative to the first piece of lumber while supporting the first piece of lumber stock on the first and second lumber supports until the first saw head and the first lumber support are located adjacent a first location along the first piece of lumber and the second saw head and the second lumber support are located adjacent a second location along the first piece of lumber; and operating the first saw head to cut a first board off the first piece of lumber stock at the first location and operating the second saw head to cut a second board off the first piece of lumber stock at the second location. 
     Some embodiments of the method further include moving, during a second period of time, the first and second saw heads and the first and second lumber supports relative to the first piece of lumber while supporting the first piece of lumber on the first and second lumber supports until the first saw head and the first lumber support are located at a third location along the first piece of lumber and the second saw head and the second lumber support are located at a fourth location along the first piece of lumber; and operating the first saw head to cut a third board off the first piece of lumber stock at the third location and operating the second saw head to cut a fourth board off the first piece of lumber stock at the fourth location. 
     In some embodiments of the method, the moving of the first saw head and the first lumber support is done such that the first saw head and the first lumber support move together along the first gantry structure at a fixed spatial relationship to one another, and the moving of the second saw head and the second lumber support is done such that the second saw head and the second lumber support move together along the first gantry structure at a fixed spatial relationship to one another. 
     In some embodiments of the method, the moving of the first saw head and the first lumber support is done such that the first saw head and the first lumber support move together along the first gantry structure at a fixed spatial relationship to one another and cut the first board off the first piece of lumber stock such that the blade of the first saw head cuts adjacent and parallel to a length of the first lumber support and such that the first lumber support continues to support the first piece of lumber stock remaining after the first board is cut off, and the moving of the second saw head and the second lumber support is done such that the second saw head and the second lumber support move together along the first gantry structure at a fixed spatial relationship to one another and cut the second board off the first piece of lumber stock such that the blade of the second saw head cuts adjacent and parallel to a length of the second lumber support and such that the second lumber support continues to support the first piece of lumber stock remaining after the second board is cut off. 
     In some embodiments of the method, the first saw head and the first lumber support rotate together around a first vertical axis and move together along the first gantry structure at a fixed spatial relationship to one another and cut the first board off the first piece of lumber stock such that the blade of the first saw head cuts adjacent and parallel to a length of the first lumber support and such that the first lumber support continues to support the first piece of lumber stock remaining after the first board is cut off, and the second saw head and the second lumber support rotate together around a second vertical axis and move together along the first gantry structure at a fixed spatial relationship to one another and cut the second board off the first piece of lumber stock such that the blade of the second saw head cuts adjacent and parallel to a length of the second lumber support and such that the second lumber support continues to support the first piece of lumber stock remaining after the second board is cut off. 
     Some embodiments of the method further include a first saw-fence post and a second saw-fence post, wherein the first saw head and the first lumber support are both connected to the first saw-fence post and wherein the second saw head and the second lumber support are both connected to the second saw-fence post; rotating the first saw head and the first lumber support together around a vertical axis of the first saw-fence post; rotating the second saw head and the second lumber support together around a vertical axis of the second saw-fence post; and urging the first piece of lumber stock against the first saw-fence post and the second saw-fence post while the first saw head cuts off the first board and the second saw head cuts off the second board. 
     Some embodiments of the method further include providing a lumber pickup arm; successively picking up at least one of a plurality of pieces of lumber stock from at least one source pile of pieces of lumber stock; moving the at least one piece of lumber stock in a direction substantially perpendicular to a long axis of the at least one piece of lumber stock; depositing the at least one piece of lumber stock onto the first and second lumber support; and urging the at least one piece of lumber stock against the first saw-fence post and the second saw-fence post. 
     Some embodiments of the method further include providing a lumber pickup arm operatively coupled to a second gantry structure, wherein the lumber pickup arm includes a first plurality of selectively air-pressure-activatable suction cups arranged in a staggered configuration; generating location parameters for where the first piece of lumber is to be picked up; and lowering the lumber pickup arm based on the location parameters of where the first piece of lumber is to be picked up so that a first sub-plurality of the first plurality of suction cups seat on the first surface of the first piece of lumber, and reducing air pressure in the first sub-plurality of the first plurality of suction cups to grab the first piece of lumber, and later increasing air pressure in the plurality of the first plurality of suction cups to release the first piece of lumber. 
     In some embodiments, the present invention provides an apparatus for sawing a first piece of lumber stock. This apparatus includes a first gantry structure having a length, a first plurality of saw heads supported by the first gantry structure including a first saw head having a blade and a second saw head having a blade; first means for supporting the first piece of lumber stock at a first location along a length of the first piece of lumber stock; second means for supporting the first piece of lumber stock at a second location along a length of the first piece of lumber stock; means for moving, during a first period of time, the first and second saw heads and the first and second lumber supports relative to the first piece of lumber while supporting the first piece of lumber stock until the first saw head and the first means for supporting are located adjacent a first location along the first piece of lumber and the second saw head and the second means for supporting are located adjacent a second location along the first piece of lumber; and means for operating the first saw head to cut a first board off the first piece of lumber stock at the first location and means for operating the second saw head to cut a second board off the first piece of lumber stock at the second location. 
     Some embodiments further include means for moving, during a second period of time, the first and second saw heads and the first and second lumber supports relative to the first piece of lumber while supporting the first piece of lumber on the first and second lumber supports until the first saw head and the first lumber support are located at a third location along the first piece of lumber and the second saw head and the second lumber support are located at a fourth location along the first piece of lumber; and means for operating the first saw head to cut a third board off the first piece of lumber stock at the third location and operating the second saw head to cut a fourth board off the first piece of lumber stock at the fourth location. 
     Some embodiments further include a lumber pickup arm; means for successively picking up at least one of a plurality of pieces of lumber stock from at least one source pile of pieces of lumber stock; means for moving the at least one piece of lumber stock in a direction substantially perpendicular to a long axis of the at least one piece of lumber stock; means for depositing the at least one piece of lumber stock onto the first and second lumber support; and means for urging the at least one piece of lumber stock against the first saw-fence post and the second saw-fence post. 
     Some embodiments further include a lumber pickup arm operatively coupled to a second gantry structure, wherein the lumber pickup arm includes a first plurality of selectively air-pressure-activatable suction cups arranged in a staggered configuration; means for generating location parameters for where the first piece of lumber is to be picked up; and means for lowering the lumber pickup arm based on the location parameters of where the first piece of lumber is to be picked up so that a first sub-plurality of the first plurality of suction cups seat on the first surface of the first piece of lumber, and reducing air pressure in the first sub-plurality of the first plurality of suction cups to grab the first piece of lumber, and later increasing air pressure in the plurality of the first plurality of suction cups to release the first piece of lumber. 
     In the exemplary embodiments here, various combinations of elements are described. Unless specifically indicated otherwise, no element is considered to be critical and one or more of the example elements may be optionally omitted. Further, it is specifically contemplated that various combinations of the various simple embodiments separately described herein may be implemented as a more complex combination of elements to implement the present invention. Further still, it is specifically contemplated that various combinations of the patents and patent applications cited herein may be combined with one or more of the various simple embodiments separately described herein to obtain a more complex combination of elements to implement the present invention. 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. Although numerous characteristics and advantages of various embodiments as described herein have been set forth in the foregoing description, together with details of the structure and function of various embodiments, many other embodiments and changes to details will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should be, therefore, determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein,” respectively. Moreover, the terms “first,” “second,” and “third,” etc., are used merely as labels, and are not intended to impose numerical requirements on their objects.