Abstract:
An automated lumber handling system 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.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of co-pending patent application Ser. No. 14/577,779 filed on Dec. 19, 2014; which is a division of patent application Ser. No. 13/136,922 filed on Aug. 15, 2011 now Pat. No. 8,960,244 issued on Feb. 24, 2015; which claims the benefit of provisional patent application Ser. No. 61/402,654 filed on Sep. 2, 2010. All of the foregoing applications are hereby incorporated herein by reference in their entirety. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The subject invention generally pertains to material handling and more specifically to retrieving individual pieces of lumber stacked at one or more locations and moving the pieces individually to another location. 
       BACKGROUND 
       [0003]    Various machines and methods have been developed for retrieving individual pieces of lumber or boards stacked at one location and feeding the boards individually to a saw. Examples of such systems are disclosed in U.S. Pat. Nos. 6,379,105 and 6,923,614. Additional lumber handling systems are disclosed in U.S. Pat. Nos. 2,730,144; 3,873,000 and 3,952,883. A lumber processing system for making prefabricated trusses and panels is disclosed in U.S. Pat. No. 7,950,316. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is a schematic top view of an example lumber handling system. 
           [0005]      FIG. 2  is a schematic top view similar to  FIG. 1  but showing an example board picker at a first retrieval position over a first-to-pick board on one stack of lumber. 
           [0006]      FIG. 3  is a schematic top view similar to  FIG. 2  but showing the board picker traveling from the first retrieval position to a first delivery position. 
           [0007]      FIG. 4  is a schematic top view similar to  FIG. 2  but showing the board picker at the first delivery position. 
           [0008]      FIG. 5  is a schematic top view similar to  FIG. 2  but showing the board picker at a second retrieval position over another first-to-pick board on another stack of lumber. 
           [0009]      FIG. 6  is a schematic top view similar to  FIG. 4  but showing the board picker at the second delivery position. 
           [0010]      FIG. 7  is a schematic top view similar to  FIG. 1  but showing various methods associated with the lumber handling system. 
           [0011]      FIG. 8  is a schematic top view similar to  FIG. 7  but showing additional methods associated with the lumber handling system. 
           [0012]      FIG. 9  is a schematic top view similar to  FIG. 7  but showing additional methods associated with the lumber handling system. 
           [0013]      FIG. 10  is a cross-sectional end view taken generally along line  10 - 10  of  FIG. 2 . 
           [0014]      FIG. 11  is a cross-sectional end view similar to  FIG. 10  but showing the board picker engaging a board. 
           [0015]      FIG. 12  is a cross-sectional end view similar to  FIG. 10  but showing the board picker&#39;s piercing tool penetrating the board. 
           [0016]      FIG. 13  is a cross-sectional end view similar to  FIG. 10  but showing the board picker lifting the board. 
           [0017]      FIG. 14  is a cross-sectional end view similar to  FIG. 10  but showing the board picker releasing the board at a delivery position. 
           [0018]      FIG. 15  is a cross-sectional end view similar to  FIG. 10  but showing one piercing tool failing to grip the board. 
           [0019]      FIG. 16  is a schematic side view showing various methods associated with the lumber handling system shown in  FIG. 1 . 
           [0020]      FIG. 17  is a schematic side view showing various methods associated with the lumber handling system shown in  FIG. 1 . 
           [0021]      FIG. 18  is a schematic side view showing various methods associated with the lumber handling system shown in  FIG. 1 . 
           [0022]      FIG. 19  is a schematic side view showing various methods associated with the lumber handling system shown in  FIG. 1 . 
           [0023]      FIG. 20  is a schematic side view showing various methods associated with the lumber handling system shown in  FIG. 1 . 
           [0024]      FIG. 21  is a schematic side view showing various methods associated with the lumber handling system shown in  FIG. 1 . 
           [0025]      FIG. 22  is a perspective view of an example board. 
           [0026]      FIG. 23  is a cross-sectional view taken along line  23 - 23  of  FIG. 22 . 
           [0027]      FIG. 24  is a schematic side view show two alternate examples of a piercing tool about to pierce a slightly tilted board 
           [0028]      FIG. 25  is a cross-sectional view of an example hole in a slightly tilted board. 
           [0029]      FIG. 26  is another cross-sectional view of an example hole in a slightly tilted board. 
           [0030]      FIG. 27  is a schematic side view showing a laser scanning a stack of lumber with a bowed board. 
           [0031]      FIG. 28  is a schematic side view similar to  FIG. 27  but showing the board more bowed. 
           [0032]      FIG. 29  is a schematic cross-sectional view showing a piercing tool attempting to pierce and lift a board with a knothole. 
           [0033]      FIG. 30  is a schematic cross-sectional view similar to  FIG. 29  but showing the piercing tool in the knothole. 
           [0034]      FIG. 31  is a schematic cross-sectional view similar to  FIG. 30  but showing the piercing tool failing to successfully lift the board. 
           [0035]      FIG. 32  is a schematic cross-sectional view similar to  FIG. 31  but showing the piercing tool being shifted over for a second attempt at piercing and lifting the board. 
           [0036]      FIG. 33  is a schematic cross-sectional view similar to  FIG. 29  but showing the piercing tool making a second attempt at piercing the board. 
           [0037]      FIG. 34  is a schematic cross-sectional view similar to  FIG. 30  but showing the piercing tool having successfully pierced the board. 
       
    
    
     DETAILED DESCRIPTION 
       [0038]      FIGS. 1-34  at least one example of a lumber handling system  10  (and/or various features and methods thereof) for feeding lumber  12  of various sizes to a downstream processing station such as, for example, a numerically controlled saw  14  such as an Omni Miser by Koskovich/MiTek Industries of Chesterfield, Mo. or a Model ALS Alpine Linear Saw by Alpine Equipment of Grand Prairie, Tex. 
         [0039]    In some examples, lumber handling system  10  is used for retrieving and delivering a board  16  having an elongate length  18 , a width  20  less than the elongate length  18 , and a thickness  22  less than width  20 , wherein elongate length  18  and width  20  define an upward facing surface  24 . Board  16  is selectively movable to a stored position  26  ( FIG. 2 ), a suspended position  28  ( FIGS. 3 and 21 ) and a delivered position  30  ( FIGS. 2, 4 and 21 ). 
         [0040]    Lumber handling system  10 , in some examples, comprises a track  32  extending in a lengthwise direction  34  (also referred to as retrieval direction  34 ) and a track follower  36  coupled to track  32 . The term, “track follower” means any structure with movement guided by a track or some other elongate member. In some examples, track follower  36  is a structural beam  38  extending laterally from track  32  and being movable in lengthwise direction  34  along track  32  between a retrieval position  40  (e.g., first retrieval position) and a delivery position  42  (e.g., first delivery position  42   a,  second delivery position  42   b,  etc.). The term, “structural” as used with reference to a beam means an elongate mechanical member, fabrication or assembly, as opposed to a light beam. Thus a “structural beam” as used throughout this patent includes, but is certainly not limited to standard I-beams, channels, fabricated framework, angles, etc. 
         [0041]    Some examples of system  10  also include a lumber support  44  (e.g., rack, cart, multi-size lumber support, shelf, etc.) with a board-supporting surface  46  supporting the weight of board  16  when board  16  is in its stored position. Some examples of system  10  also include a piercing tool  48  coupled to structural beam  38  and being movable therewith along lengthwise direction  34 . The term, “piercing tool” means any member adapted to penetrate wood. Examples of piercing tool  48  include, but are not limited to, a screw  48   a,  a pointed pin  48   b  (e.g., a nail), a dagger, lance, single point blade, multipoint blade, prong, etc. Piercing tool  48 , in some examples, comprises a lower tip  50 . In some examples, piercing tool  48  is movable up and down between a release position  52  and a penetrated position  54  relative to upward facing surface  24  of board  16 . In some examples, lower tip  50  of piercing tool  48  is appreciably above upper surface  24  and spaced apart from board  16  when piercing tool  48  is in release position  52  while structural beam  38  is in a first retrieval position  40   a  and board  16  is in stored position  26 . In some examples, lower tip  50  is appreciably below upper surface  24  and penetrating upper surface  24  when piercing tool  48  is in penetrated position  54  while structural beam  38  is in first retrieval position  40   a  and board  16  is in a first stored position  26   a.  In some examples, lower tip  50  is appreciably below upper surface  24  and penetrating upper surface  24  when piercing tool  48  is in penetrated position  54  while board  16  is in suspended position  28  hanging from piercing tool  48 . In some examples, lower tip  50  is appreciably below upper surface  24  and penetrating upper surface  24  when piercing tool  48  is in penetrated position  54  while board  16  is in suspended position  28  hanging from piercing tool  48  and while structural beam  38  is partway between first retrieval position  40   a  and first delivery position  42   a,  as shown in  FIGS. 3 and 19 . In some examples, lower tip  50  is appreciably above upper surface  24  and spaced apart from board  16  when piercing tool  48  is in the release position  52 . 
         [0042]    In some examples, system  10  also includes a tool carrier  56  coupling piercing tool  48  to structural beam  38  such that tool carrier  56  is movable up and down between a raised position ( FIGS. 10, 13 and 14 ) and a lowered position ( FIGS. 11, 12 and 15 ) relative to structural beam  38 . In some examples, an actuator  58  (e.g., pneumatic cylinder, hydraulic cylinder, linear motor, drive screw, rack-and-pinion, etc.) drives the movement of tool carrier  56  relative to beam  38 . In some examples, a sliding guide  60  guides the movement of tool carrier  56  relative to beam  38 . 
         [0043]    In some examples, system  10  also includes a tool mount  62  coupling piercing tool  48  to tool carrier  56  such that tool mount  62  is movable up and down between a retracted position ( FIGS. 10, 11, 14  and right side of  FIG. 15 ) and an extended position ( FIGS. 12, 13  and left side of  FIG. 15 ) relative to tool carrier  56 . In some examples, an actuator  64  (e.g., pneumatic cylinder, hydraulic cylinder, linear motor, drive screw, rack-and-pinion, etc.) drives the movement of tool mount  62  relative to tool carrier  56 . In some examples, tool mount  62  is mounted in substantially vertical sliding relationship with tool carrier  56 . 
         [0044]    In some examples, particularly in cases where piercing tool  48  is screw  48   a,  a motor  66  (e.g., pneumatic motor, hydraulic motor, electric motor, etc.) rotatably couples piercing tool  48  to tool mount  62 , tool carrier  56 , and/or beam  38  so that piercing tool  48  can be rotated relative to beam  38  and board  16 . In some examples, motor  66  includes a gear reducer for rotating piercing tool  48  slower than a motor rotor of motor  66 . In some examples, motor  66  is reversible for selectively screwing and unscrewing screw  48   a.    
         [0045]    As for various methods pertaining to the examples illustrated in  FIGS. 1-34 , arrows  68  and  70  of  FIG. 16  provide at least one example of placing a board on a lumber support. Arrows  72 ,  74  and  76  of  FIG. 24  and arrow  78  of  FIG. 33  provide at least one example of driving a piercing tool downward through an upward facing surface of the board such that the piercing tool penetrates the board to become fastened thereto. Arrow  80  of  FIG. 13  provides at least one example of raising piercing tool  48  with board  16  fastened thereto, thereby lifting board  16  from lumber support  44  while board  16  hangs suspended from piercing tool  48 . Arrow  82  of  FIG. 3 , arrows  84  and  86  of  FIG. 19 , and arrows  88  and  90  of  FIG. 21  provide at least one example of, while a board hangs from piercing tool  48 , moving piercing tool  48  and the board hanging therefrom in translation from above one or more lumber supports  44  to delivery position  30 . Arrows  92  and  94  of  FIG. 14  provide at least one example of extracting piercing tool  48  from board  16 , thereby releasing board  16  at delivery position  30 . In some examples, a conveyor  96  and/or a board-receiving elevator is at delivery position  30  to receive board  16  and ultimately transfer board  16  to saw  14 . Holes  98  shown in  FIGS. 1, 14, 25 and 26  provide at least one example of: upon extracting piercing tool  48  from a board leaving pierced hole  98  in the board, wherein pierced hole  98  has an average width  100  at upward facing surface  24  and a pierced depth  102 . In some examples, pierced depth  102  is at least three times greater than average width  100 . The term, “average width” (e.g., average width  100 ) is defined as the square root of [(4×A)/pi], wherein “A” is the cross-sectional area of the hole (e.g., hole  100 ) at board surface  24 . So, for round holes, the average width is the hole&#39;s diameter at upward facing surface  24 . 
         [0046]    In some examples where piercing tool  48  is screw  48   a,  driving piercing tool  48   a  downward  72  through upward facing surface  24  of board  16  and extracting (arrows  92  and  94 ) piercing tool  48  from board  16  involves turning  104  screw  48 a as illustrated by arrows  104  of  FIGS. 11 and 24  and arrows  106  of  FIG. 14 . 
         [0047]    In some examples, arrows  108  and  110  provide at least one example of cutting the board into a plurality of smaller pieces  112 ,  114 ,  116 , 118  and  120 . Arrows  122  and  124  of  FIG. 1  provide at least one example of assembling the plurality of smaller pieces into an assembly, wherein the assembly, in some examples, is a roof truss  126  or a wall panel  128 . In  FIG. 1 , holes  98  left in truss  126  provide at least one example of leaving pierced hole  98  exposed in the assembly, wherein the exposed pierced hole  98  provides a telltale indication of the assembly&#39;s manufacturing process and the equipment used therein. In some examples where lumber  12  is loaded onto a lumber support with board-supporting surface  46  that is slightly tilted (e.g., two degrees from level with reference to earth&#39;s gravity) to urge a stack of lumber  12  to lean back (e.g., two degrees from vertical with reference to earth&#39;s gravity) against a back support  130  to help prevent the stack from falling forward, a resulting pierced hole  98  in board  16  defines a longitudinal centerline  132  displaced out of perpendicularity with upward facing surface  24  (e.g., displaced an angle  134  of about two degrees), as illustrated by  FIGS. 24-26 . 
         [0048]    In some examples, as illustrated in  FIGS. 15 and 29-34 , system  10  makes two or more attempts at picking up a board if the first attempt fails.  FIGS. 29 and 30  show that prior to driving piercing tool  48  downward through upward facing surface  24  of board  16  such that piercing tool  48  penetrates board  16  to become fastened thereto (as shown in  FIG. 12 ), failing to effectively fasten piercing tool  48  to board  16 , thereby executing a failed attempt at piercing board  16 , wherein  FIG. 29  shows piercing tool  48  being lowered into board  16 , and  FIG. 30  shows a discrepancy (e.g., a void, a knot hole  136 , crack, soft area of wood, hard impenetrable area, etc.) that prevents piercing tool  48  from fastening itself to board  16 .  FIG. 31  and the right side of  FIG. 15  provide at least one example showing piercing tool  48  rising without board  16 , and a sensor  138  (e.g., proximity switch associated with actuator  64  or tool mount  62 , electromechanical limit switch, photoelectric eye, etc.) on the right side of  FIG. 15  senses that piercing tool  48  is at its release position, thereby providing at least one example of recognizing the failed attempt.  FIG. 32  provides at least one example showing, in response to recognizing the failed attempt, retracting  94  piercing tool  48 ; and after retracting  94  piercing tool  48 , shifting  140  the piercing tool horizontally a predetermined offset distance  142 .  FIGS. 33 and 34  provide at least one example showing, after shifting  140  piercing tool  48  horizontally the predetermined offset distance  142 , driving (represented by arrows  78  and  104 ) piercing tool  48  downward through upward facing surface  24  of board  16  such that piercing tool  48  penetrates board  16  to become fastened thereto, as shown in  FIG. 34 . 
         [0049]    Referring to  FIGS. 16-21 , in some examples, arrow  68  of  FIG. 16  provides at least one example showing stacking a first plurality of boards  144  on a first lumber support  44 a to create a first stack of lumber  146  ( FIG. 17 ) having a first upper contour  148 , wherein the first plurality of boards  144  have a first size (size being characterized by length  18  and/or width  20 , as shown in  FIG. 22 ). Arrow  70  of  FIG. 16  provides at least one example showing stacking a second plurality of boards  150  on a second lumber support  44   b  to create a second stack  152  of lumber having a second upper contour  154 , wherein the second plurality of boards  150  has a second size that in some examples is different than the first size of the first plurality of boards  144 . A laser beam  156  and arrows  158  of  FIGS. 17 and 18  provide at least one example showing laser scanning first upper contour  148  and second upper contour  154 . Arrow  160  in conjunction with a controller  162 , shown in  FIG. 17 , provides at least one example showing creating a first digital profile  164  representing first upper contour  148 . Arrow  160  in conjunction with controller  162 , shown in  FIG. 18 , provides at least one example showing creating a second digital profile  166  representing second upper contour  154 . Based on first digital profile  164  and second digital profile  166 , arrow  168  ( FIG. 17 ) and arrow  170  ( FIG. 18 ) in conjunction with controller  162  provides at least one example showing identifying a first-to-pick board (e.g., boards  16 a and  16 b) of each of the first stack of lumber  146  and the second stack of lumber  152 . In some examples, controller  162  includes software (e.g., program, algorithm, code, etc.) that identifies the first-to-pick board as being, for a given stack of lumber, a top layer board that is closest to the board&#39;s delivered position  30 . In some examples, controller  162  is programmed to also execute an algorithm  172  shown in  FIG. 1 , wherein a block  174  illustrates generating and inputting  176  a board request  178  of a predetermined size; a block  180  illustrates determining which of the first size and the second size matches the predetermined size; block  182  illustrates: depending on which of the first size and the second size matches the predetermined size, directing a board picker  184  to at least one of the first stack of lumber  146  and the second stack of lumber  152  and further directing board picker  184  to the first-to-pick board  16   a  or  16   b  of those stacks of lumber. Board picker  184  is schematically illustrated to represent any apparatus capable of lifting board  16  up from a lumber support or stack of lumber. One example of board picker  184  is piercing tool  48  coupled to and carried by structural beam  38 . Arrows  84  and  86  of  FIG. 19  provides at least one example showing board picker  184  picking up first-to-pick board  16   b  and transporting it from the second stack of lumber  152  to a delivered position  30  spaced apart from the first stack of lumber  146  and the second stack of lumber  152 . 
         [0050]      FIG. 17  illustrates one example of displaying a digital image  186  of the first digital profile  164  on a digital display  188  (computer monitor, touchscreen, etc.), and  FIG. 18  illustrates one example of displaying a digital image  190  of the second digital profile  154  on digital display  188 . 
         [0051]    In some examples, first-to-pick board  16   a  and/or  16   b  is board  16  shown in  FIG. 22 , wherein board  16  has an elongate length  18  (e.g., 6-20 feet), a width  20  (e.g., 4-12 inches nominal) less than elongate length  18 , and a thickness  22  (e.g., 2 inches nominal) less than width  20 . Width  20  extends between opposite longitudinal edges  192  of the first-to-pick board; the opposite longitudinal edges  192  are substantially parallel to each other; and the first-to-pick board, in some examples, also has a wane  194  extending along and interrupting one of the opposite longitudinal edges  192 . The term, “wane,” means the presence of bark or abnormal lack of wood at the edge of a board. A wane is often a prominently beveled defect created by a board being cut from a tree trunk near the trunk&#39;s outer periphery. Arrow  196  of  FIG. 23  provides at least one example showing establishing a target location  198  for board picker  184  to engage the first-to-pick board, wherein target location  198  is substantially midway between the opposite edges  192  of the first-to-pick board.  FIG. 23  and dashed line  200  of  FIG. 22  provides at least one example showing laser scanning wane  194  but disallowing wane  194  to alter target location  198 . 
         [0052]      FIGS. 20 and 21  provide at least one example showing a board picker  184  fetching  202  a second board  16  from second stack of lumber  152  or delivering  204  second board  16  to delivered position  30 . Referring to  FIGS. 20 and 21 , line  156  and arrows  202  and  204  provide at least one example showing second-pass laser scanning  156  the first upper contour  148  of the first stack of lumber  146  while board picker  184  is in a process of fetching  202  second board  16  from the second stack of lumber  152  or in the process of delivering  204  second board  16  to delivered position  30 . Arrows  206  and  208  provide at least one example showing updating the first digital profile  164 ′ based on the second-pass laser scanning  156  of the first upper contour  148  of the first stack of lumber  146 . 
         [0053]      FIGS. 27 and 28  show one example of a stack of lumber  210  having a bowed board  16   c  that bows upward to define an uppermost point  212  of an upper contour  214  as determined by laser scanning  156  of upper contour  214 .  FIGS. 27 and 28  also show at least one example of interposing bowed board  16   c  laterally between two adjacent boards  16   d  and  16   e  in stack of lumber  210 , wherein bowed board  16   c  protrudes upward a bowed distance  216  above the two adjacent boards  16   d  and  16   e  as determined by laser scanning  156  upper contour  214 . Dimension  218  of  FIGS. 27 and 28  provides at least one example showing defining a predetermined distance  218 . Arrow  220  of  FIG. 28  provides at least one example showing identifying bowed board  16   c  as the first-to-pick board of stack of lumber  210  if bowed distance  216  is greater than predetermined distance  218 . Arrow  252  of  FIG. 27  provides at least one example showing identifying another board (e.g., a board  16   f ) other than bowed board  16   c  as the first-to-pick board of stack of lumber  210  if bowed distance  216  is less than predetermined distance  218 . 
         [0054]      FIGS. 7-9  illustrate convenient means for loading and replenishing lumber supports  44  with stacks of lumber. The drawing figures show board picker  184  being movable horizontally along board retrieval direction  34 , the plurality of lumber supports  44  being movable horizontally in a lateral direction  224  traversing board retrieval direction  34 , at least one material handling vehicle  226 , and delivery position  42 . The term, “direction” as used with reference to “board retrieval direction,” “lateral direction,” “vertical direction,” etc., encompasses an infinite set of parallel lines in space (e.g., straight parallel lines or curved parallel lines), and covers moving either way along any of the lines, e.g., moving in a vertical direction encompasses moving up and down, and not necessarily just upward. The term, “material handling vehicle,” means any lumber transporter. Examples of a material handling vehicle include, but are not limited to, a forklift truck, manual forklift, pallet truck, pallet jack, dolly, cart, stacker, walkie stacker, etc. 
         [0055]    Dashed lines provide at least one example of defining a work area  228  and defining a service area  230  laterally offset to work area  228 . Arrows  232  of  FIG. 7  provide at least one example of segregating lumber by board size to create a plurality of lumber stacks  146 ,  152  and  234  that are distinguishable by board size. Lines  236  of  FIG. 7  provide at least one example of loading the plurality of lumber stacks  146 ,  152  and  234  on the plurality of lumber supports  44  such that each lumber support  44  of the plurality of lumber supports holds one of the plurality of lumber stacks  146 ,  152  or  234 . Lines  238  provide at least one example of defining a plurality of shuttle paths  238  extending in lateral direction  224  between work area  228  and service area  230 , wherein the plurality of shuttle paths  238 , in some examples, correspond in quantity to the plurality of lumber supports  44 . Arrows  240  provide at least one example of selectively translating the plurality of lumber supports  44  individually between work area  228  and service area  230  and doing so via the plurality of shuttle paths  238 . Arrows  242  of  FIG. 1  provide at least one example of board picker  184  repeatedly translating in board retrieval direction  34  over work area  228 , thereby transporting a plurality of boards individually from the plurality of lumber stacks in the work area  228  to delivered position  30 . Arrows  242  are shown slightly curved simply for illustration to show that board picker  184  travels over the stacks of lumber and pausing at certain points (e.g., points  244  and/or  246 ) to pick up chosen boards. Arrows  248  and  250  of  FIG. 8  provide at least one example of material handling vehicle  226  replenishing a chosen lumber support  44   b  or  44   c  of the plurality of lumber supports  44 . Arrow  252  of  FIG. 8  provides at least one example of moving one lumber support  44   c  of the plurality of lumber supports  44  from work area  228  to service area  230 , wherein lumber support  44   c  travels along one shuttle path of the plurality of shuttle paths  238 . Arrows  248  and  250  provide at least one example of material handling vehicle  226  traveling in board retrieval direction  34  to deliver an additional set of boards  152 ′ or  234 ′ to the chosen lumber support, wherein the chosen lumber support is in either work area  228  and/or service area  230 . Arrow  254  provides at least one example of moving the one lumber support  44   c  of the plurality of lumber supports  44  from service area  230  back to work area  228 , wherein the one lumber support  44   c  travels along the one shuttle path  238 . In some examples, the chosen lumber support is the one lumber support  44   c,  as indicated by arrow  250  showing material handling vehicle  226  traveling in service area  230  toward chosen lumber support  44   c.  In some examples, the chosen lumber support and the one lumber support  44   c  are two separate lumber supports, as indicated by arrow  248  showing material handling vehicle  226  traveling in work area  228  toward chosen lumber support  44   b.  In some examples, as illustrated in  FIGS. 1 and 7-9 , lumber supports  44  are manually portable wheeled carts. Arrows  252 ,  254 ,  256  and  258  provide at least one example of manually  260  moving wheeled cart lumber supports between work area  228  and service area  230 . 
         [0056]    Arrow  68  of  FIG. 16  with further reference to  FIGS. 24-26  provides at least one example showing placing a board on a lumber support such that an upward facing surface  24  of the board is tilted at an incline, as indicated by angle  134 . The term, “incline” means tilted out of perpendicularity with earth&#39;s gravity, e.g., upward facing surface  24  is not perpendicular to earth&#39;s gravity and thus surface  24  is not level. Arrow  76  of  FIG. 24 , arrow  72  of  FIG. 11 , and  FIG. 12  provide at least one example showing driving piercing tool  48  in a downward direction  72  through the upward facing surface  24  of the board such that piercing tool  48  penetrates the board to become fastened thereto. Arrow  80  of  FIG. 13  provides at least one example showing raising piercing tool  48  with the board fastened thereto, thereby lifting the board from lumber support  44  while the board hangs suspended from piercing tool  48 . Arrows  84  and  86  of  FIG. 19  provide at least one example showing, while the board hangs from piercing tool  48 , moving piercing tool  48  and the board in translation from above the lumber support to a delivery position. Arrows  92  and  94  of  FIG. 14  provide at least one example showing extracting piercing tool  48  from the board, thereby releasing the board at delivery position  30 . 
         [0057]      FIG. 17  provides at least one example showing laser scanning  156  upper contour  148  of a stacked plurality of boards. Lines  160 ,  262  and the displayed image  186  on controller  162  as shown in  FIGS. 1 and 17  provide at least one example showing creating a digital profile  164  representing upper contour  148  and displaying a digital image  186  of digital profile  164 , but displaying digital image  186  such that the stacked plurality of boards  146  appear to be level rather than tilted. 
         [0058]    In some examples, as shown in  FIGS. 1 and 16-21 , system  10  includes separate lumber supports  44  and a multi-size lumber support  264 . In some examples, each lumber support  44  holds lumber of a single board size (e.g., same nominal length and width), and the board size in any one lumber support  44  differs from the others. In addition, multi-size lumber support  264  has multiple compartments for holding relatively small quantities of odd or less common board sizes (multi-size lumber support  264  holds a supplementary plurality of boards  16  of various sizes). 
         [0059]      FIG. 1  with further reference to  FIGS. 7-9  provide at least one example showing positioning the plurality of lumber stacks in work area  228  such that a plurality of boards of the plurality of lumber stacks lie substantially perpendicular to a predefined imaginary plane  266  and are substantially centrally justified relative to the imaginary plane even while some boards of the plurality of boards are longer than other boards of the plurality of boards.  FIG. 1  and  FIGS. 16-21  provide at least one example showing storing a supplemental plurality of boards  16  in multi-size lumber support  264  disposed in work area  228 , wherein the supplemental plurality of boards  16  have an assortment of board lengths that differ from that of the lumber on the plurality of separate lumber supports  44 . Block  174  of  FIG. 1  provides at least one example showing generating a board request  178  for a set of boards of various sizes (e.g., set of board includes board-A and board-B), wherein the set of boards of various sizes includes a supplemental board (e.g., board-A) from multi-size lumber support  264  and at least one board (e.g., board-B) from the plurality of boards stacked on the plurality of separate lumber supports. Arrows  242  and  268  of  FIG. 1  provide at least one example showing board picker  184  repeatedly translating in board retrieval direction  34  over work area  228 , thereby transporting the set of boards (e.g., including board-A and board-B) individually from the plurality of lumber stacks  44  and multi-size lumber support  264  in work area  228  to delivered position  30 . In  FIG. 1 , arrows  242  and  268  each shown splitting provide at least one example showing board picker  184  selectively delivering to each of the two delivered positions  30   a  and  30   b,  wherein the two delivered positions feed two separate saws  14 . 
         [0060]    In some examples, additional items perhaps worth noting include items  270  in  FIGS. 10-15 , which provide a stop or point of engagement between tool carrier  56  and upper surface of a board. Examples of items  270  include, but are not limited to, a hard pad, a soft pad, a bumper, a serrated gripper, and any board-engaging lower surface of tool carrier  56 . In some examples, items  270  help hold a board steady as piercing tool  48  approaches and is driven into the board. The term, “pierce” and derivatives thereof mean at least partially penetrating. 
         [0061]    In some examples, hole  98  having a depth  102  that is at least three times greater than the hole&#39;s diameter or average width helps ensure that piercing tool  48 , after being driven into the board, will remain stuck in the hole without an external member having to hold the piercing tool in the hole (e.g., the board can hang from piercing tool  48 ), yet piercing tool  48  can be forcibly extracted later. For greater holding force, in some examples, two piercing tools  48  are driven into board  16  along converging or diverging paths. 
         [0062]    In some examples, structural beam  38  is supported in a cantilever manner from track  32 . In some examples, structural beam  38  is part of a gantry with vertical support at both ends. In other examples, tool carrier  56  is suspended from an overhead monorail extending along plane  266 . In some examples, such a monorail is supported by one or more stationary cantilevers having one end anchored to a wall or floor-mounted vertical post. 
         [0063]    In some examples, as shown in  FIG. 1 , a drive system  272  positions and powers the movement of structural beam  38  along track  32 , wherein drive system  272  comprises a cogged belt  274  supported between a drive cogged wheel  276  and an idler cogged wheel  278  with opposite ends of belt  274  being attached directly or indirectly to beam  38  and with drive wheel  276  coupled to a motor  280 . In some examples, motor  280  is a model AM3042-1G00-000 servomotor by Beckhoff of Verl, Germany. 
         [0064]    In response to various inputs, controller  162  controls various components of system  10  including, but not limited to, controlling motor  280  via an output  282 , controlling board picker  184  and various actuators thereof, controlling a laser unit  284 , and controlling digital display  188 . Controller  262  is schematically illustrated to present any electrical device able to provide various outputs in response to various inputs. Examples of controller  262  include, but are not limited to, a computer, a PLC (programmable logic controller), etc. A specific example of controller  262  is a model CP6201-0001-0200 industrial computer by Beckhoff of Verl, Germany. 
         [0065]    Laser unit  284  is schematically illustrated to present any device that emits a laser beam  156  for sensing a distance between a surface and the laser emitting device. An example of laser unit  284  includes, but is not limited to, a model RF603-260/1250-232-I-IN-AL-CC-3 laser triangulation position sensor provided by Riftek of Minsk, Russia. Input  286  and output  288  schematically represent control communication between controller  282  and laser unit  284 . Upon scanning the upper profile of stacks of lumber to identify the first-to-pick board of a particular stack, laser unit  284  also identifies the location of each stack of lumber relative to each other and/or in relation to delivery position  30  because controller  162  being in communication with motor  280  and laser unit  284  can correlate laser scan readings with the position of board picker  184 . 
         [0066]    Input  290  and output  292  schematically represent control communication between controller  162  and board picker  184  (and its various components), wherein the board picker&#39;s various components include sensors  138 , motor  66 , and actuators  58  and  64 . An example of sensor  138  includes, but is not limited to, a model NBB5-18GM60-A2-V1 inductive sensor provided by Pepperi-Fuchs of Mannheim, Germany. 
         [0067]    Some examples of the lumber handling system/method are defined as follows: 
       Example-1 
       [0068]    A lumber handling system for retrieving and delivering a board having an elongate length, a width less than the elongate length, and a thickness less than the width, wherein the elongate length and the width define an upward facing surface, the board being selectively in a stored position, a suspended position and a delivered position, the lumber handling system comprising: 
         [0069]    a track extending in a lengthwise direction; 
         [0070]    a track follower coupled to the track, the track follower being movable in the lengthwise direction along the track between a first retrieval position and a first delivery position; 
         [0071]    a lumber support with a board-supporting surface supporting the weight of the board when the board is in the stored position; 
         [0072]    a piercing tool coupled to the track follower and being movable therewith along the lengthwise direction, the piercing tool comprising a lower tip, the piercing tool being movable up and down between a release position and a penetrated position relative to the upward facing surface of the board; 
         [0073]    the lower tip of the piercing tool being appreciably above the upper surface and spaced apart from the board when the piercing tool is in the release position while the track follower is in the first retrieval position and the board is in the stored position; 
         [0074]    the lower tip of the piercing tool being appreciably below the upper surface and penetrating the upper surface of the board when the piercing tool is in the penetrated position while the track follower is in the first retrieval position and the board is in the stored position; 
         [0075]    the lower tip of the piercing tool being appreciably below the upper surface and penetrating the upper surface of the board when the piercing tool is in the penetrated position while the board is in the suspended position hanging from the piercing tool; 
         [0076]    the lower tip of the piercing tool being appreciably below the upper surface and penetrating the upper surface of the board when the piercing tool is in the penetrated position while the board is in the suspended position hanging from the piercing tool and while the track follower is partway between the first retrieval position and the first delivery position; and 
         [0077]    the lower tip of the piercing tool being appreciably above the upper surface and spaced apart from the board when the piercing tool is in the release position. 
       Example-2 
       [0078]    The lumber handling system of example-1, wherein the piercing tool comprises a screw. 
       Example-3 
       [0079]    The lumber handling system of example-1, further comprising a tool carrier coupling the piercing tool to the track follower, the tool carrier being movable up and down between a raised position and a lowered position relative to the track follower. 
       Example-4 
       [0080]    The lumber handling system of example-3, further comprising a tool mount coupling the piercing tool to the tool carrier, the tool mount being movable up and down between a retracted position and an extended position relative to the tool carrier. 
       Example-5 
       [0081]    A lumber handling method comprising: 
         [0082]    placing a board on a lumber support; 
         [0083]    driving a piercing tool downward through an upward facing surface of the board such that the piercing tool penetrates the board to become fastened thereto; 
         [0084]    raising the piercing tool with the board fastened thereto, thereby lifting the board from the lumber support while the board hangs suspended from the piercing tool; 
         [0085]    while the board hangs from the piercing tool, moving the piercing tool and the board in translation from above the lumber support to a delivery position; 
         [0086]    extracting the piercing tool from the board, thereby releasing the board at the delivery position; and 
         [0087]    upon extracting the piercing tool from the board, leaving a pierced hole in the board, the pierced hole having an average width at the upward facing surface and a pierced depth, the pierced depth being at least three times greater than the average width. 
       Example-6 
       [0088]    The lumber handling method of example- 5 , wherein the piercing tool comprises a screw, and driving the piercing tool downward through the upward facing surface of the board and extracting the piercing tool from the board involves turning the screw. 
       Example-7 
       [0089]    The lumber handling method of example-5, wherein the piercing tool comprises a pointed prong. 
       Example-8 
       [0090]    The lumber handling method of example-5, further comprising: 
         [0091]    cutting the board into a plurality of smaller pieces; 
         [0092]    assembling the plurality of smaller pieces into an assembly, wherein the assembly is at least one of a roof truss and a wall panel; and 
         [0093]    leaving the pierced hole exposed in the assembly. 
       Example-9 
       [0094]    The lumber handling method of example-5, wherein the pierced hole defines a longitudinal centerline displaced out of perpendicularity with the upward facing surface. 
       Example-10 
       [0095]    The lumber handling method of example-5, further comprising: 
         [0096]    prior to driving the piercing tool downward through the upward facing surface of the board such that the piercing tool penetrates the board to become fastened thereto, failing to effectively fasten the piercing tool to the board, thereby executing a failed attempt at piercing the board; 
         [0097]    recognizing the failed attempt; 
         [0098]    upon recognizing the failed attempt, shifting the piercing tool horizontally a predetermined offset distance; and 
         [0099]    after shifting the piercing tool horizontally the predetermined offset distance, driving the piercing tool downward through the upward facing surface of the board such that the piercing tool penetrates the board to become fastened thereto. 
       Example-11 
       [0100]    A lumber handling method comprising: 
         [0101]    stacking a first plurality of boards on a first lumber support to create a first stack of lumber having a first upper contour, the first plurality of boards having a first size; 
         [0102]    stacking a second plurality of boards on a second lumber support to create a second stack of lumber having a second upper contour, the second plurality of boards having a second size; 
         [0103]    laser scanning the first upper contour and the second upper contour; 
         [0104]    creating a first digital profile representing the first upper contour; 
         [0105]    creating a second digital profile representing the second upper contour; 
         [0106]    based on the first digital profile and the second digital profile, identifying a first-to-pick board of each of the first stack of lumber and the second stack of lumber; 
         [0107]    generating a board request of a predetermined size; 
         [0108]    determining which of the first size and the second size matches the predetermined size; 
         [0109]    depending on which of the first size and the second size matches the predetermined size, directing a board picker to one of the first stack of lumber and the second stack of lumber; 
         [0110]    further directing the board picker to the first-to-pick board of one of the first stack of lumber and the second stack of lumber; 
         [0111]    the board picker picking up the first-to-pick board; and 
         [0112]    transporting the first-to-pick board from one of the first stack of lumber and the second stack of lumber to a delivered position spaced apart from the first stack of lumber and the second stack of lumber. 
       Example-12 
       [0113]    The lumber handling method of example-11, further comprising displaying a digital image of at least one of the first digital profile and the second digital profile on a digital display. 
       Example-13 
       [0114]    The lumber handling method of example-11, wherein the first-to-pick board has an elongate length, a width less than the elongate length, and a thickness less than the width, the width extending between opposite longitudinal edges of the first-to-pick board, the opposite longitudinal edges being substantially parallel to each other, the first-to-pick board also having a wane extending along and interrupting one of the opposite longitudinal edges, the lumber handling method further comprising: 
         [0115]    establishing a target location for the board picker to engage the first-to-pick board, the target location being substantially midway between the opposite edges of the first-to-pick board; and 
         [0116]    laser scanning the wane but disallowing the wane to alter the target location. 
       Example-14 
       [0117]    The lumber handling method of example-11, further comprising: 
         [0118]    the board picker doing at least one of fetching a second board from the second stack of lumber and delivering the second board to the delivered position; 
         [0119]    second-pass laser scanning the first upper contour of the first stack of lumber while the board picker is in a process of at least one of fetching the second board from the second stack of lumber and delivering the second board to the delivered position; 
         [0120]    updating the first digital profile based on the second-pass laser scanning of the first upper contour of the first stack of lumber. 
       Example-15 
       [0121]    The lumber handling method of example- 11 , wherein first stack of lumber includes a bowed board that bows upward to define an uppermost point of the first upper contour as determined by laser scanning of the first upper contour, the lumber handling method further comprising: 
         [0122]    interposing the bowed board laterally between two adjacent boards in the first stack of lumber; 
         [0123]    the bowed board protruding upward a bowed distance above the two adjacent boards as determined by laser scanning of the first upper contour; 
         [0124]    defining a predetermined distance; 
         [0125]    identifying the bowed board as the first-to-pick board of the first stack of lumber if the bowed distance is greater than the predetermined distance; and 
         [0126]    identifying another board other than the bowed board as the first-to-pick board of the first stack of lumber if the bowed distance is less than the predetermined distance. 
       Example-16 
       [0127]    A lumber handling method involving the use of lumber, a board picker movable horizontally along a board retrieval direction to and from a delivered position, a plurality of lumber supports movable horizontally in a lateral direction traversing the board retrieval direction, a material handling vehicle and a board receiving area, the lumber handling method comprising: 
         [0128]    defining a work area; 
         [0129]    defining a service area laterally offset to the work area; 
         [0130]    segregating the lumber by board size to create a plurality of lumber stacks that are distinguishable by board size; 
         [0131]    loading the plurality of lumber stacks on the plurality of lumber supports such that each lumber support of the plurality of lumber supports holds one of the plurality of lumber stacks; 
         [0132]    defining a plurality of shuttle paths extending in the lateral direction between the work area and the service area, the plurality of shuttle paths corresponding to the plurality of lumber supports; 
         [0133]    via the plurality of shuttle paths, selectively translating the plurality of lumber supports individually between the work area and the service area; 
         [0134]    the board picker repeatedly translating in the board retrieval direction over the work area, thereby transporting a plurality of boards individually from the plurality of lumber stacks in the work area to the delivered position; and 
         [0135]    the material handling vehicle replenishing a chosen lumber support of the plurality of lumber supports by: 
         [0136]    a) moving one lumber support of the plurality of lumber supports from the work area to the service area, wherein the one lumber support travels along one shuttle path of the plurality of shuttle paths; 
         [0137]    b) the material handling vehicle traveling in the board retrieval direction to deliver an additional set of boards to the chosen lumber support, wherein the chosen lumber support is in one of the work area and the service area; and 
         [0138]    c) moving the one lumber support of the plurality of lumber supports from the service area back to the work area, wherein the one lumber support travels along the one shuttle path. 
       Example-17 
       [0139]    The lumber handling method of example-16, wherein the one lumber support is the chosen lumber support, and the material handling vehicle traveling in the board retrieval direction to deliver the additional set of boards to the chosen lumber support travels into the service area. 
       Example-18 
       [0140]    The lumber handling method of example-16, wherein the one lumber support and the chosen lumber support are two separate lumber supports, and the material handling vehicle traveling in the board retrieval direction to deliver the additional set of boards to the chosen lumber support travels into the work area. 
       Example-19 
       [0141]    The lumber handling method of example-16, wherein the plurality of lumber supports are a plurality of wheeled carts, and selectively translating the plurality of lumber supports individually between the work area and the service area is done manually. 
       Example-20 
       [0142]    A lumber handling method comprising: 
         [0143]    placing a board on a lumber support such that an upward facing surface of the board is tilted at an incline; 
         [0144]    driving a piercing tool in a downward direction through the upward facing surface of the board such that the piercing tool penetrates the board to become fastened thereto; 
         [0145]    raising the piercing tool with the board fastened thereto, thereby lifting the board from the lumber support while the board hangs suspended from the piercing tool; 
         [0146]    while the board hangs from the piercing tool, moving the piercing tool and the board in translation from above the lumber support to a delivery position; and 
         [0147]    extracting the piercing tool from the board, thereby releasing the board at the delivery position. 
       Example-21 
       [0148]    The lumber handling method of example-20, wherein the downward direction is angularly displaced out of perpendicularity with the upward facing surface. 
       Example-22 
       [0149]    The lumber handling method of example-20, wherein the board is part of a plurality of boards stacked on the lumber support, the plurality of boards each being tilted at the incline of the upward facing surface of the board, the method further comprising: 
         [0150]    laser scanning an upper contour of the plurality of boards; 
         [0151]    creating a digital profile representing the upper contour; and 
         [0152]    displaying a digital image of the digital profile, but displaying the digital image such that the plurality of boards appear to be level rather than tilted. 
       Example-23 
       [0153]    A lumber handling method involving the use of lumber, a board picker movable horizontally along a board retrieval direction to and from a delivered position, a plurality of separate lumber supports, and a multi-size magazine, the lumber handling method comprising: 
         [0154]    defining a work area; 
         [0155]    segregating the lumber by board size to create a plurality of lumber stacks that are distinguishable by board size, wherein board length and board width are two characteristics of board size; 
         [0156]    loading the plurality of lumber stacks on the plurality of separate lumber supports such that each separate lumber support of the plurality of separate lumber supports holds one of the plurality of lumber stacks of a given board size; 
         [0157]    defining an imaginary vertical plane extending along the board retrieval direction; 
         [0158]    positioning the plurality of lumber stacks in the work area such that a plurality of boards of the plurality of lumber stacks lie substantially perpendicular to the imaginary plane and are substantially centrally justified relative to the imaginary plane even while some boards of the plurality of boards are longer than other boards of the plurality of boards; 
         [0159]    storing a supplemental plurality of boards in the multi-size magazine disposed in the work area, the supplemental plurality of boards having an assortment of board lengths that differ from that of the lumber on the plurality of separate lumber supports; 
         [0160]    generating a board request for a set of boards of various sizes, wherein the set of boards of various sizes includes a supplemental board from the multi-size magazine and at least one board from the plurality of boards stacked on the plurality of separate lumber supports; and 
         [0161]    the board picker repeatedly translating in the board retrieval direction over the work area, thereby transporting the set of boards individually from the plurality of lumber stacks and the multi-size magazine in the work area to the delivered position. 
       Example-24 
       [0162]    The lumber handling method of example-23, wherein the delivered position is one of two delivered positions, and the lumber handling method further comprises the board picker selectively delivering to each of the two delivered positions, wherein the two delivered positions feed two separate saws. 
         [0163]    Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of the coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.