Patent Publication Number: US-2021187779-A1

Title: Workpiece cutting equipment hanging over the top of workpieces

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     USPTO Provisional Patent Application No.:  62 / 951 , 409   
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     FIELD OF THE INVENTION 
     The present invention generally relates to machines and processes for cutting logs into lumber or timber. 
     BACKGROUND OF THE INVENTION 
     Conventional machines and processes for cutting logs into lumber or timber present many inefficiencies, performance limitations, and maintenance issues. Novel machines and processes for cutting logs into lumber or timber are commercially needed. The present invention presents many advantages over existing machines and processes. 
     SUMMARY OF THE INVENTION 
     The present invention includes many aspects and features. 
     According to at least one other aspect of the invention, in accordance with at least one embodiment thereof, is provided an infeed portion, a curve chipping and profiling portion, a curve sawing gang portion and an outfeed portion arranged in series thereof for managing, transporting and processing a cant, or already minimally processed tree or log into lumber, or boards. 
     The workpiece processing equipment hanging over the top of the workpieces consists of a support frame with guide rails and bearings and a means of motion and constrains, mounted above the workpieces being processed. The profiling curve sawing gang hanging over the top of workpieces uses an overhead support structure which the processing equipment, meaning the cutting tools and or saws, are mounted to. The processing equipment is mounted to linear guide rails which allows the equipment to translate in a direction perpendicular to the flow of the workpieces. The path at which the equipment follows is determined by a 3D scanner and optimizer that decides what the workpiece or cant, will be processed into. The scanner can see the geometric shape of the cant, including its curvature and the optimizer calculates the most valuable solution including the curvature path of the cant. The processing equipment can then follow the curvature path of the cants, yielding the highest recovery of the cant fiber. 
     The profiling curve sawing gang hanging over the top of the workpiece has an improved canting and profiling method over the existing methods. The canter consists of two heads that rotate opposite of each other and are arranged with one head above the other and offset to allow an overlap, without hitting each other. This allows for a simple drive method using drive lines and belts. The overlap, or match line of the canter heads is adjustable, and raises or lowers depending on the cant thickness being processed to equalize the cutting forces. The profiling heads and also driveshaft driven and are vertically adjustable depending on the provided optimizer solution. This assembly is mounted on an overhead support structure. 
     The profiling curve sawing gang has an improved method of curve sawing cants over the existing methods. The curve sawing gang assembly is mounted to an overhead structure on linear rails and bearings that allow the assembly to move perpendicular to the flow of the workpieces. The curve sawing gang saw box is much smaller in size and mass than all other machines in the past. All of the mass is very close to the saw box pivot, allowing the machine to make more accurate sets and in less time. The saw box uses all electric actuation which would not be possible if the machine what mounted below the workpieces due the simple fact that contamination is an issue with electric actuators. The electric actuators are mounted above the cutting tools, keeping them out of harms way. The pivot of the curve sawing gang is mounted on the carriage that translates the saw box perpendicular to the flow. This is the opposite of all other machines. This allows the saws to have a more predictable path, since they travel in only one direction during an angled translation move. 
     The curve sawing gang assembly has an improved saw guide clamping system. This system uses hollow shaft hydraulic cylinders to clamp the guides. This allows for the clamping component to be perfectly concentric with the guide clamping face. Having one large clamping face eliminate the problems of the prior method which uses a three- pusher setup that is known to clamp the guide stack out of square, making poor lumber and burning up saws. 
     The curve sawing gang assembly also has an automatic locking and unlocking arbor door for saw access and saw changes. This is done through spring engaged, hydraulic release actuators for the door, and the arbor tapered nose cone. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The included drawings are for illustrative purposes and serve only to provide examples of possible structures and process operations for one or more implementations of this disclosure. These drawings in no way limit any changes in form and detail that may be made by one skilled in the art without departing from the spirit and scope of this disclosure. A more complete understanding of the subject matter may be derived by referring to the detailed description and claims when considered in conjunction with the following figures, wherein like reference numbers refer to similar elements throughout the figures. 
         FIG. 1  is an elevation section view of the overall Profiling Curve Sawing Gang hanging over the top of the workpiece, with flow showing from right to left. The section is taken about the centerline of the workpiece feed. 
         FIG. 2  is an elevation section view of the infeed and canter/profiler module and a mid-feed module, with flow showing from right to left. The section is taken at the centerline of the workpiece feed. 
         FIG. 3  is an elevation section view of the Curve sawing gang with outfeed module, with flow showing from right to left. The section is taken at the centerline of the workpiece feed. 
         FIG. 4  is an elevation view of the canter profiler module and infeed module looking with the direction of flow. 
         FIG. 5  is an elevation side view of the curve sawing gang with a section view about the “A” section line. 
         FIG. 6  is an elevation side view of the curve sawing gang saw box with a section view about the “B” section line. 
         FIG. 7  is the detail view “A” from  FIG. 6 . 
         FIG. 8  is the section view about section line “C” from  FIG. 6 . 
         FIGS. 9-43  are various embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION AND BEST MODE OF IMPLEMENTATION 
     The included drawings are for illustrative purposes and serve only to provide examples of possible structures and process operations for one or more implementations of this disclosure. These drawings in no way limit any changes in form and detail that may be made by one skilled in the art without departing from the spirit and scope of this disclosure. A more complete understanding of the subject matter may be derived by referring to the detailed description and claims when considered in conjunction with the following figures, wherein like reference numbers refer to similar elements throughout the figures. 
     Referring to  FIG. 1 , the preferred embodiment for Workpiece processing equipment hanging over the top of a workpiece is shown in the form of a profiling curve sawing gang. The profiling Curve sawing gang consists of an Infeed module  1 , canter/profiler module  2  hanging over the top of a workpiece  6 , mid-feed module  3 , curve sawing gang  4  hanging over the top of a workpiece  6 , and an outfeed module  5 . 
     Looking now at  FIG. 1  and  FIG. 2 , the canter/profiler module  2  is mounted to an overhead support structure  7  by way of linear rails  8 , and linear bearings  9 . Overhead support structure  7 , linear rails  8  and linear bearings  9  are all mounted above the workpiece feedline  10 . The linear rails  8  and linear bearings  9  allow the canter/profiler module  2  to move linearly, perpendicular to the direction of flow  12 . The canter/profiler module contains a pivot  14  which allows the canter/profiler to pivot around the curvature of the cant. The canter heads  11  are configured one over the top of the other and offset in the direction of flow  12  to allow the heads to overlap without interference and are counter rotating in relation to each other. The canter heads  11  have a canter lift cylinder  13  which moves the canter heads  11  match line to always ne in the middle of the cant thickness, equalizing the cutting forces. The top profiling head  15  and bottom profiling head  16  are placed immediately downstream of the canter heads  11 . The top profiling head  15  has a top profiling head positioning cylinder  17  to allow the top profiling head  15  to adjust to different positions depending on the optimizer solution. The bottom profiling head  16  has a bottom profiling head positioning cylinder  18  to allow the bottom profiling head  16  to adjust to different positions depending on the optimizer solution. The top profiling head  15  and bottom profiling head  16  pivot with the canter heads  11  on the same pivot  14 , and have an additional profiler pivot  19  that allows the profiling heads to pivot slightly off of the main pivot  14  to allow the profiling heads to match the curvature of the cants. The workpiece  6  is driven and maintained by powered feed rolls  20  mounted in the infeed module  1  and mid-feed module  3 . 
     Looking now to  FIG. 2  and  FIG. 4 , there is a right-hand canter/profiler module  21  and a left-hand canter/profiler module  22 , both mounted on the same overhead support structure  7 , which is supported by the infeed module  1  and mid-feed module  3 . The overhead support structure  7 , linear rails  8  and linear bearings  9  are all mount above the workpiece feedline  10 . 
     Referring now to  FIG. 1 ,  FIG. 3  and  FIG. 5 , the curve sawing gang  3  hanging over the top of the workpiece  6  is mounted to a linear shaft  22  and rides on linear bearings  23 . The linear shaft  22  is mounted to the overhead support structure  24  that is supported by the out feed module  5  and the mid feed module  3 . The linear bearings  23  are attached to the curve sawing gang carriage  25 , that translates in a perpendicular direction to the flow of the workpiece. The curve sawing gang carriage  25  contains a pivot bearing drive assembly  26  that allows the curve sawing gang saw box  27  to pivot plus or minus six degrees to allow the saws  28  to follow the curvature of a cant. The overhead support structure  24 , linear shaft  22  and linear bearings  23  are all mounted over the top of the workpiece feed line  29 . The workpiece  6  is driven and controlled by the powered feed rolls  20 . 
     Referring to  FIG. 3  and  FIG. 5 , the curve sawing gang  3 , uses an electric servo motor  30  coupled to a ball nut  31  by way of a timing belt  32 . The ball nut  31  is attached to the overhead support structure  24  by way of a bearing housing  33 . The ball nut  31  drives a ball screw  34  that is fixed to the curve sawing gang carriage  25 . The ball screw  34  does not rotate, allowing the ball nut  31  to achieve higher speeds due to removal of the ball screw  34  whipping motion that is typical of long length shafts spinning at high RPMs. This ball nut  31  and ball screw  34  assembly moves the curve sawing gang  3  in the perpendicular direction relative to the flow of the workpiece. The curve sawing gang  3  pivot motion is driven by a second servo motor  35  that is attached to the curve sawing gang carriage  25  and coupled to a driveshaft assembly  36  which is attached to the pivot bearing drive assembly  26 . The pivot bearing drive assembly  26  contains a large diameter four-point contact bearing that is twenty-five inches in diameter in this example. The pivot bearing drive assembly  26  also contains a worm gear that drives the outer race of the four-point contact bearing. The drive shaft assembly  36  is directly coupled to the worm gear, resulting in angular motion of the curve sawing gang saw box  27  about the saw box pivot axis  37  that is concentric to the pivot bearing drive assembly  26 . 
     Referring to  FIG. 5 , the curve sawing gang  3  has saw arbors  38  that provide power to the saws  28 . In this example, the curve sawing gang  3  contains two saw arbors  38 . The saw arbors  38  are driven by electric motors  39 , one electric motor  39  per saw arbor  38 . The electric motors  39  are coupled to the saw arbors  38  by way of a timing belt  40 . The electric motors  39  are mounted to a pivoting motor base  41  that is coupled to the curve sawing gang saw box  27  and the pivot bearing drive assembly  26  by way of a pivoting coupler assembly  42 . The electric motors  39  are mounted very close to the saw box pivot axis  37  and rotate with the curve sawing gang saw box  27 . 
     Looking at  FIG. 6  and  FIG. 7  the curve sawing gang saw box  27  has an arbor door  42  that opens to gain access to the saws  28  and saw guides  43 . The arbor door  42  opens on a pivot bearing  44  and a linear bearing  45  and linear rail  46 . The arbor door  42  is shown in the closed position. When the arbor door  42  is closed, it is clamped shut using clamping mechanisms  47  that are spring engaged, hydraulically released. The clamping mechanisms  47  are attached to the arbor door  42  by way of machined housings  48 . The clamping mechanisms  47  clamp the arbor door  42  against the curve sawing gang saw box door side-side plate  49 . The clamping mechanisms  47  mate with a tapered pull stud  50  that is bolted to the curve sawing gang saw box door-side side plate  49 . The arbor door  42  supports one end of the saw arbor  38  with a bearing assembly  51 . The saw arbor  38  has a male tapered end  52  that mates to the arbor nose cone  53  that is fastened to the bearing assembly  51 . The bearing assembly  51  is fastened to the arbor door  42 . The arbor nose cone  53  pulls tight against the male tapered end  52  with a pull stud mechanism  54 . The pull stud mechanism  54  uses conical washers  55  that apply force to a draw bar  56  that is attached to a hardened ball retainer  57 . There are hardened balls  58  spaced equidistant around the diameter of the draw bar  56 . Attached to the saw arbor  38  is an arbor pull stud  59 . The arbor pull stud  59  has a tapered feature that the hardened balls  58  come into contact with when the conical washers  55  push the hardened ball retainer  57  away from the pull stud  59 , causing the arbor nose cone  53  to pull tight against the male tapered end  52  of the saw arbor  38 . To open the arbor door  42 , first, hydraulic pressure releases the four clamping mechanisms  47 , then there is a hydraulic cylinder  60  that when actuated, presses against the draw bar  56 , collapsing the conical washers  55 . When the hardened ball retainer  57  that is attached to the draw bar  56  hits the pull stud  59 , it pushes the arbor nose cone  53  away from the male tapered end  52  of the saw arbor  38 . 
     Referring now to  FIG. 8  the curve sawing gang saw box has saw guides  43  that hold the saws  28  in predetermined locations to obtain a specific sawn board size. The saw guides  43  are supported by a saw guide shaft  60 . The saw guide shaft  60  is mounted to the curve sawing gang saw box  27  by the saw guide clamp arm  61  which is mounted to the curve sawing gang saw box  27  by the saw guide clamp arm  62 . On the curve sawing gang door side  64 , there is a saw guide shaft rod  63  that is attached to the saw guide shaft  60 . The saw guide shaft rod  63  has a threaded end  65  that a saw guide spacer  66  is clamped and attached to, mating the saw guide shaft  60  and the saw guide clamp arm  62 . On the curve sawing gang saw box drive  67  side the saw guide spacer  66  is replaced by a hydraulic cylinder  68 . Furthermore, attached to the saw guide spacer clamp nut  69  there is an electric actuator  70  that is attached to the curve sawing gang saw box drive side by way of round shaft stand offs  71 . The electric actuator  70  positions the saw guide shaft  60  and in turn all the saw guides  43  and saws  28  as well as the curve sawing gang saw box door side  64  saw guide clamp arm  62 . When the hydraulic cylinder  68  is actuated only the cylinder body  72  moves. The hydraulic cylinder rod  73  is fixed relative to the position of the electric actuator  70 . When the hydraulic cylinder body  72  moves it moves the curve sawing gang saw box drive side  67  saw guide clamp arm  61  moves with it clamping the stack of saw guides  74  concentrically against the curve sawing gang saw box door side  64  saw guide clamp arm  61 . The electric actuator  70  can be replaced with a manual adjuster  75 . Actuating the hydraulic cylinder  68  in the opposite direction as discussed will result in an unclamping action for saw changes. 
     The invention encompasses gang saws, gang edger, board edger, canter, chipper, profiler, circular twin, circular quad and many other industry names; as well as straight sawing, curve sawing, slew sawing and all other forms of sawing or chipping logs into lumber. The present invention involves said machinery being mounted above the workpieces (logs) that are being processed into lumber. The workpiece cutting equipment hanging over the top of the workpieces in profiling curve sawing gang application is a machine that is used to cut, chip or saw a cant into lumber. 
     There are many advantages of the present invention in comparison to conventional machines and processes, including but not limited to the following advantages. 
     When trees or logs are processed into lumber or boards, the equipment used must be installed on a foundation of some kind, conventionally, below the workpieces. A cant is a log that has been through the first step of breakdown in a sawmill, commonly referred to as the primary breakdown stage. What turns a log into a cant is the process of cutting or chipping two parallel faces onto the log. The profiling curve sawing gang will receive the cant with the parallel faces horizontally orientated. The profiling curve sawing gang can then chip a second pair of parallel faces perpendicular to the first horizontal faces. A profile of a board will then be cut into said second pair of parallel faces, typically one on each face. The profiling curve sawing gang will then use the gang saw portion of the machine with saws rotating about a horizontal axis, to saw the remaining portion of the cant into boards of a predetermined thickness. 
     Conventionally, all workpiece cutting equipment in the sawmill industry is mounted below the workpiece. There is an extremely large amount of debris that is produced from processing logs into lumber. One of the advantages of the current invention is that such debris does not pile up on the equipment reducing the life of components and increasing cleanup time for the sawmills, and the invention allows the possibility of using superior actuators to position the cutting tools and makes it easier to access the machinery for maintenance. 
     Conventionally, profiling curve sawing gang machines have two directions of motion. They pivot for the first direction which is angular, and a second direction which is linear and can be perpendicular to the workpiece flow. For the curve sawing gang machine, the pivot point is fixed to the centerline of the workpiece flow. The second direction is only perpendicular to the workpiece flow, if the curve sawing gang pivot is set to zero degrees. The amount the curve sawing gang can pivot is +/−6 degrees. This means that the second direction angle will be +/−6 degrees to workpiece flow. When the curve sawing gang is moving at an angle, the saws that are mounted inside of the curve sawing gang saw box are in fact moving in two directions relative to the workpiece. This makes matching the profiled board shape to the saws more difficult, even though this motion is accounted for in the motion calculation. The present invention makes matching the profiled board shape to the saws easier and more precise. 
     Another aspect of conventional equipment used to process logs or tress into lumber or boards is the need to change saws and guides. This is done by opening a door that is also the bearing support for the saw arbors. The door is fastened to the saw box wall with tapered bolts that mate to a female taper in the saw box wall to align the door and arbor bearings to the fixed opposing saw box wall. This has multiple downsides including the potential to unsafely open the door while the arbor is still turning due to the manual nature of the operation. Another downside is the time it takes to manually perform this operation. The saw filer changing the saws must get a tool to remove the bolts, typically there are 4 of them. Once all the bolts are removed and placed into a receptacle for safe keeping, the saw filer must then get a pusher bolt and install it into the end of the arbor to push the door open, off the arbor. Saw changes typically happen numerous times throughout the day depending on various sawing conditions. This means a lot of time being spent taking out bolts and putting them back in. These tapered bolts and female receivers are high wear items that when not replaced necessarily will cause arbor misalignment and premature bearing failures as well as poor sawing performance. The present invention avoids these downsides of such conventional equipment. 
     Conventionally, saw guides locate the saws in predetermined locations to produce an accurate thickness of lumber or boards. Such saw guides are supported by a saw guide shaft which locates the saw guides relative to the arbor axis. There is also a saw guide anti-rotate bar which keep the saw guide in a rotationally acceptable position relative to the saw guide shaft axis. Furthermore, there is a saw guide clamp adjustable, and clamping ends. The saw guide clamp assembly generally consists of a hydraulic clamp cylinder attached to three round shaft pushers spaced equidistant around the guide clamp hydraulic cylinder and guide clamp surface. This has many downsides, mainly in that when the shaft pushers wear, or are not perfectly adjusted, the guides are able to shift, causing poor saw alignment and reduced guide life contributing to poor sawing performance. The present invention avoids these downsides of such conventional equipment.