Patent ID: 12194582

DETAILED DESCRIPTION

Embodiments of a frame splining system apparatus and method for fitting substrate onto a frame to form a screen are described. The frame splining system may comprise a splining head assembly apparatus suspended from a longitudinal gantry. The splining head assembly apparatus may comprise a splining head configured to position and press a spline into a track configured in a frame. The splining head assembly apparatus may traverse along the longitudinal gantry under influence of a splining head drive motor, and transversely along lateral gantries under influence of a gantry drive motor. This may allow the splining head to traverse the entire periphery of the frame. The splining head may also rotate around a vertical axis in order to traverse the corners of the frame. The splining head may further traverse vertically to engage and disengage from the frame.

The splining head comprises a feed from the spline spool, a positioning wheel, a substrate cutting wheel, a pressing wheel, and a spline cutter. The splining head maneuvers to position an end of the spline above a track running around the perimeter of the frame. The track has an outer edge that is the edge more distal from the center axis of the frame. The positioning wheel presses the spline part-way into the track. The substrate cutting wheel simultaneously cuts the substrate adjacent to the spline along the outer edge of the track. As the splining head traverses along the track, positioning the spine and cutting the substrate, the pressing wheel runs behind the positioning wheel and the substrate cutting wheel. The pressing wheel is of a greater radius or has a lower central axis, such that it presses the spline more deeply into the track of the frame. The action of the pressing wheel seats the spline into its final position and causes the cut edge of the substrate to retract into the track. When the desired length of spline has been fitted into the track, the spline cutter (e.g., a solenoid-actuated blade) is engaged to cut the length of spline, the final end of which is pressed into the track. When approaching each corner, the splining head lifts up to disengage the pressing wheel from the track, then rotates ninety degrees to bend the spline around the corner and into the track, repeating this process for each corner of the frame.

A barcode, a quick response (QR) code, or other indicator (e.g., serial number or other informational label) on the frame to be screened may be scanned, or the frame may be otherwise analyzed, providing the frame splining system with the frame dimensions. The frame splining system may comprise a substrate carousel of substrate spool pins of different widths supporting one or more substrate spools. Based on the frame dimensions indicated by the barcode, the frame splining system may adjust the substrate carousel so that the appropriate substrate spool is aligned with the work surface, and the substrate thereon may be engaged by the grabbing bar for fitting onto the frame. The grabbing bar may utilize air pistons to pinch and hold an edge of the substrate while drawing the substrate off of the substrate spool across the frame on the work surface.

Clamps may be utilized to engage the frame to hold it securely in place on the work surface, preventing movement in any direction. The clamps may be automatically positioned based on the scanned size of the frame.

FIG.1Adepicts an isometric view of a frame splining system100in one embodiment. The frame splining system100may comprise lateral gantries102, a longitudinal gantry104, and a gantry drive motor106for positioning a splining head assembly apparatus200that includes a spline spool pin124holding a spline spool126, and a splining head300. The frame splining system100may further comprise a substrate carousel108including one or more substrate spool pins110holding one or more substrate spools112. The frame splining system100may comprise a work surface114configured to receive and support a frame118, and frame securement clamps116for securing the frame in place. The frame splining system100may comprise a grabbing bar120configured to traverse the work surface114along grabbing bar rails122in order to grab hold of the substrate from one of the substrate spools112of the substrate carousel108. Finally, the frame splining system100may be controlled via a control station132.

In one embodiment, the splining head assembly apparatus200may be moved across the horizontal plane by the action of the gantry drive motor106, which may propel the longitudinal gantry104across the lateral gantries102, as well as by the action of a splining head drive motor (illustrated with respect toFIG.2) which may propel the splining head assembly apparatus200along the longitudinal gantry104. In this manner, the splining head assembly apparatus200may be moved along the track of a frame118positioned on the work surface114, such that the splining head300(illustrated in greater detail with respect toFIG.3BandFIG.3C) may position spline within the track so as to anchor substrate to the frame.

The frame splining system100may in one embodiment include a substrate carousel108containing more than one substrate spool pin110. This substrate carousel108may allow multiple substrate spools112to be selected for use. For example, substrates136of different widths may be mounted within the substrate carousel108. In one embodiment, the frame splining system100may include a scanning device130capable of scanning a frame118on the work surface114for a barcode, a quick response (QR) code, or some other dimension-indicating label. The scanning device130may be able to capture an image of the frame and may do so alongside a measuring scale. The scanning device130may communicate with and provide input to a controller capable of determining the frame dimensions from the scanned data. The controller134may in one embodiment reside in the control station132.

The frame splining system100may thus be configured to automatically select a spool holding an appropriately sized substrate from among the substrate spools112in the substrate carousel108based on the frame dimensions so detected. The splining head assembly apparatus200may be manipulated in three dimensions over the work surface114to engage with a frame118based on the frame dimensions detected via the scanning device130.

FIG.1Bdepicts an isometric detail view of a frame splining system100in accordance with one embodiment. The work surface114and frame118may be seen more clearly, along with the frame securement clamps116, which may traverse the work surface114to contact the edges of the frame118in order to hold the frame118immobile against the work surface114as the splining head assembly apparatus200splines the frame.

The grabbing bar120may also be seen more clearly. An arrow indicates the grabbing bar motion128along the grabbing bar rail122. The grabbing bar motion128along the grabbing bar rail122may carry the grabbing bar120toward the substrate carousel108shown inFIG.1A. The grabbing bar120may advance along the grabbing bar rail122, and, when proximate to the substrate carousel108, grab onto a free edge of substrate wound on a substrate spool112(shown inFIG.1A).

The grabbing bar120may use a pinching or gripping contact to engage the substrate. In one embodiment, where the substrate is a mesh, the grabbing bar120may use a hooking feature to engage with the mesh. Once engaged with the substrate, the grabbing bar120may withdraw along the grabbing bar rail122in order to pull the substrate across frame118residing on the work surface114.

FIG.1Cdepicts a front view of a frame splining system100in accordance with one embodiment. In this view, substrate136is shown, after it has been engaged by the grabbing bar120and pulled across the frame118and work surface114, such that the frame118is overlaid with the substrate136and ready for splining.

FIG.1Ddepicts a right-side view of a frame splining system100in accordance with one embodiment.FIG.1Edepicts a top view of a frame splining system100in accordance with one embodiment.

FIG.2depicts the splining head assembly apparatus200in greater detail. The splining head assembly apparatus200may comprise a spline spool pin124, a spline spool126, and a splining head300, such as those introduced with respect toFIG.1Aand described in greater detail with regard toFIG.3AthroughFIG.3C. The splining head assembly apparatus200may further comprise a splining head drive motor202, a vertical support204, a vertical positioning actuator206, a spline208, a cover210, a spline director212, a splining head pivot belt214, a splining head pivot actuator216, a vertical support218, a spline spool pin support arm224, a top housing220, a housing222, a support226, a support228, a bracket230, a bracket232, and a bracket234.

The splining head drive motor202may propel the splining head assembly apparatus200along the longitudinal gantry104introduced with respect toFIG.1A. Through this action and that of the gantry drive motors106moving the longitudinal gantry104along the lateral gantries102, the splining head assembly apparatus200may be moved across the horizontal plane and along the track of the frame. The vertical support204holds the splining head300vertically secure within the splining head assembly apparatus200.

The vertical support204may be configured to rotate such that the splining head300may be repositioned as the track changes direction within the frame. In one embodiment, the vertical support204may rotate into four fixed positions, each ninety degrees apart, so as to change splining direction at each of the four corners of the track of a rectangular frame. In another embodiment, the vertical support204may freely rotate across three hundred and sixty degrees, and may continually change direction to accomplish splining of an arching or elliptical track or portions of the track. This may be accomplished in one embodiment through the action of the splining head pivot actuator216. The splining head pivot actuator216may be a motor configured to induce revolutions of a splining head pivot belt214that in turn may rotate the vertical support204around its vertical axis, causing a rotation of the splining head300. The vertical support204and splining head300may be configured such that this rotation does not twist the spline208enough to cause tension or distortion either within the splining head assembly apparatus200or once positioned and pressed into the frame. Such configuration will be well understood by one of ordinary skill in the art.

Through the action of the vertical positioning actuator206, the splining head assembly apparatus200and thus the splining head300may be moved up and down vertically, so as to engage and disengage the splining head300with the frame track. The vertical positioning actuator206may be a solenoid, an air piston, some other type of linear actuator, or some other type of motive device capable of maintaining the splining head assembly apparatus200at a constant vertical height as it traverses the horizontal plane.

The spline spool126may hold a length of spline208in readiness to be fed into the track of the frame by the splining head300. A spline spool126may hold a length of spline208long enough to assemble many spline frames. A spool may, for example, hold 250 feet (76 m) of spline, such that many frames may be assembled without needing to stop the frame splining system100and load a new spline spool126on the spline spool pin124. The spline spool pin support arm224may support the spline spool pin124and spline spool126in a manner that keeps these elements stationary with respect to the other elements of the splining head assembly apparatus200. The spline208may be fed from spline spool126to a spline director212, which directs the spline208along an appropriate path while preventing the spline208from undergoing any tension that might deform the spline208.

Spline may come in a number of standardized diameters such that frames of different makes and manufacturers may be splined with splines of different manufacturers, allowing a simpler and more streamlined and efficient assembly process for multiple types of frames. For example, frames of differing lengths, widths, and depths, may all be configured with tracks that accept 0.12-inch (3-mm) spline, while other frames may be configured to accept 0.18-inch (5-mm) spline. The elements of the splining head300may be designed to work with multiple spline sizes or may be interchangeable to accommodate individual spline sizes, as will be well understood by one skilled in the art.

Spline may be made of a malleable material such as rubber, intended to compress within the track for a tight fit. As such, tension on the spline may cause it to stretch, and thereby reduce in diameter. Such distortions may negatively impact the fit of the spline in the track, and thus the quality of the finished frame. A cover210may protect the elements of the splining head assembly apparatus200from impact as frames are placed and removed from the work surface.

Housing plates, supports, and brackets (220-234) may provide mechanical and structural support in accordance with the needs of the functional elements of the splining head assembly apparatus200described above. The configuration of thee elements shown here is not intended to be limiting, as one of ordinary skill in the art will appreciate.

FIG.3Aillustrates an exploded view of a splining head300in accordance with one embodiment. The splining head300may comprise a pressing wheel302, a pressing wheel guide304, a pressing wheel actuator306, a spline cutter actuator308, a spline cutter guide310, a housing312, a top housing314, a spline feeding motor316, a stepper wheel318, a spring housing320, a spring322, a substrate cutting wheel324, a positioning wheel326, a spline cutter slide328, a front roller330, a spline cutter housing332, a spline cutter334, a spline cutter slide336, and a spline cutter arm338. A number of fasteners, such as pins, screws, bolts, etc., may be used to assemble these elements as indicated by the dashed lines. Bearings may be used to facilitate the free movement of rotational parts. While these are not illustrated herein, one of ordinary skill in the art will readily apprehend the configurations and variations in which they may be used.

The pressing wheel302and pressing wheel guide304may act together to press spline into a track of a frame, as illustrated inFIG.3BandFIG.3C. The pressing wheel actuator306may provide an appropriate downward force upon the pressing wheel302in order to seat the spline within the track.

A spline cutter actuator308may act on the spline cutter334within the splining head300in order to cut the spline as the splining head assembly apparatus200and splining head300reach the end of the track in a frame being splined. In one embodiment, the spline may be cut at each corner. The spline cutter guide310, the spring housing320, the spring322, the spline cutter slide328, the spline cutter housing332, the spline cutter slide336, and the spline cutter arm338may be used to position and control the spline cutter334in a manner to configure the spline cutter334to cut the spline at appropriate points as the splining head300traverses a splined frame.

The housing312and top housing314may contain and attach to the other elements of the splining head300so as to appropriately protect and position these elements with respect to each other and the rest of the splining head assembly apparatus200and frame splining system100. In one embodiment, the spline may run through a channel in the housing312such that it may be acted upon by the spline feeding motor316as well as the spline cutter334.

The spline feeding motor316may propel the spline along the appropriate channel through the rotation of the stepper wheel318, feeding spline to the splining head300at a constant rate without placing tension on the spline, stretching it, radially compressing it, or otherwise axially or radially distorting the spline. In one embodiment, the spline may run within the vertical support204from the spline director212introduce inFIG.2to the splining head300.

The substrate cutting wheel324and positioning wheel326be rotated in coordination with a front roller330in order to position the spline and cut the substrate as is illustrated in greater detail inFIG.3BandFIG.3C.

FIG.3BandFIG.3Cdepict the splining head300in more detail according to one embodiment. The positioning wheel326may position the spline208along the track340within a frame118, as shown. The spline208may be fed through a spline feeding mechanism342such that it may be positioned along the track without any axial or radial distortion of the spline208. A substrate cutting wheel324may run along the outer edge of the frame346and may cut through substrate136. In one embodiment, the substrate cutting wheel324may cut partially through the depth of the substrate136, leaving part of the substrate depth uncut, so that the substrate136may be weakened enough for excess to be cleanly removed, without cutting completely through the substrate and potentially scratching, marring, or otherwise damaging the frame118. In one embodiment, the positioning wheel326and the substrate cutting wheel324are coaxial, as shown. In this manner, substrate136may be cut at the same time as the spline is positioned.

The positioning wheel326and substrate cutting wheel324may be configured to run ahead of a pressing wheel302. The pressing wheel302may be of larger diameter, may be set at a lower vertical height, or may otherwise be configured to press the spline208down such that it is fully seated within the track340. In some embodiments, the track340may have ridges along its sides or a lip at its top edge, such that an inserted spline208may not be easily dislodged. Just as additional force may be needed to remove a spline208from such a track340, additional force may be needed to press the spline208into such a track340, as will be well understood by those skilled in the art. A pressing wheel actuator306, as introduced with respect toFIG.2, may be used to exert a consistent downward force at the pressing wheel302, such that the spline208is fully seated in track340. The pressing wheel actuator306may also allow the pressing wheel302vertical position to be varied in one embodiment. In another embodiment, variation in pressing wheel302height may be adjusted by using a different diameter pressing wheel302for different spline sizes.

By virtue of the pressing wheel302following the substrate cutting wheel324, as the spline208is pressed into the track340, the cut edge of the substrate136may also be pressed into the track340. This is indicated inFIG.3C. Retracting the cut substrate edge into the frame represents a benefit over conventional solutions. Waste of substrate may be reduced. Tearing and dislodgment of the substrate from the frame through snagging the loose edge may be prevented. Where substrate material may have sharp edges, this edge retraction may also prevent injury to those handling the assembled frames.

The spline feeding mechanism342may incorporate or be adjacent to a spline cutter334. The spline cutter334may be controlled by the spline cutter actuator308previously introduced in order to cut the spline208at the end of a portion of the track344, such as at the corners of the track340, when approaching the portion of the track where splining began, or as otherwise necessitated by a particular action or embodiment. In one embodiment, the spline cutter334may be a single sharp blade. In another embodiment, the spline cutter334may incorporate opposing blades which the spline208is pinched between. A laser or other cauterizing element, or any other severing device may be used to sever the spline208cleanly at a predetermined point along the track340, as will be well understood by one skilled in the art.

FIG.4illustrates a routine400that may be performed by the disclosed splining head assembly apparatus, such as the splining head assembly apparatus200previously described. In block402, a splining head, such as the splining head300illustrated in detail inFIG.3BandFIG.3C, may be positioned over a track within a frame covered with a substrate. The splining head may comprise a positioning wheel, a pressing wheel, and a substrate cutting wheel.

In block404, a spline may be fed to the splining head via a spline feeding mechanism. In one embodiment, the spline may be held on and fed from a spline spool, such as that introduced with respect toFIG.1A. Spline may vary in diameter as is appropriate to the tracks of frames being splined. Spline may be made from various materials, but may commonly be of an elastic material such as rubber.

In block406, the positioning wheel positions the spline within the track. In block408, the substrate cutting wheel cuts the substrate along an outer edge of the frame. In one embodiment, the positioning wheel and the substrate cutting wheel may be coaxial, such that the spline positioning and substrate cutting occur at the same time.

In block410, the spline and the cut substrate edge may be pressed into the track using the pressing wheel. This may prevent the free edge of the substrate from snagging on objects and being damaged or displaced from the track. This may also prevent sharp-edged substrates from causing injury to those handling the assembled frames.

In block412, a spline cutter may cut the spline when an end of the track is reached. In one embodiment, spline may be cut at the corners of a track. The spline cutter may be the spline cutter334previously described and may be actuated by the afore-described spline cutter actuator.

In one embodiment, the splining head assembly apparatus may be incorporated into a frame splining system, such as the frame splining system100illustrated inFIG.1A-FIG.1E. The method may then also include scanning the frame to discover its frame dimensions. A substrate spool carrying an appropriately sized substrate may be selected from among a plurality of substrate spools configured in a substrate carousel based on the frame dimensions. The substrate carousel may be mechanically repositioned to present the substrate spool carrying the appropriately sized substrate for use. The method may also include advancing a grabbing bar along a grabbing bar rail to engage with the substrate on a substrate spool and covering the frame with the substrate by retracting the grabbing bar along the grabbing bar rail to draw the substrate across a work surface holding the frame.

In one embodiment, positioning the spline within the track and cutting the substrate along the outer edge of the frame may be performed at the same time, because the positioning wheel and the substrate cutting wheel are configured coaxially. The substrate cutting wheel may be configured to cut through less than the entire depth of the substrate, in order to prevent any scratching, cutting, marring, or other damage to the frame. The method may further include tearing away excess substrate along the cut substrate edge. Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.

LISTING OF DRAWING ELEMENTS

100frame splining system102lateral gantry104longitudinal gantry106gantry drive motor108substrate carousel110substrate spool pin112substrate spool114work surface116frame securement clamp118frame120grabbing bar122grabbing bar rail124spline spool pin126spline spool128grabbing bar motion130scanning device132control station134controller136substrate200splining head assembly apparatus202splining head drive motor204vertical support206vertical positioning actuator208spline210cover212spline director214splining head pivot belt216splining head pivot actuator218vertical support220top housing222housing224spline spool pin support arm226support228support230bracket232bracket234bracket300splining head302pressing wheel304pressing wheel guide306pressing wheel actuator308spline cutter actuator310spline cutter guide312housing314top housing316spline feeding motor318stepper wheel320spring housing322spring324substrate cutting wheel326positioning wheel328spline cutter slide330front roller332spline cutter housing334spline cutter336spline cutter slide338spline cutter arm340track342spline feeding mechanism344end of a portion of the track346outer edge of the frame400routine402block404block406block408block410block412block

Within this disclosure, different entities (which may variously be referred to as “units,” “circuits,” other components, etc.) may be described or claimed as “configured” to perform one or more tasks or operations. This formulation—[entity] configured to [perform one or more tasks]—is used herein to refer to structure (i.e., something physical, such as an electronic circuit). More specifically, this formulation is used to indicate that this structure is arranged to perform the one or more tasks during operation. A structure may be said to be “configured to” perform some task even if the structure is not currently being operated. Thus, an entity described or recited as “configured to” perform some task refers to something physical. The term “configured to” is not intended to mean “configurable to.” Reciting in the appended claims that a structure is “configured to” perform one or more tasks is expressly intended not to invoke 35 U.S.C. § 112(f) for that claim element. Accordingly, claims in this application that do not otherwise include the “means for” [performing a function] construct should not be interpreted under 35 U.S.C § 112(f).

As used herein, the term “based on” is used to describe one or more factors that affect a determination. This term does not foreclose the possibility that additional factors may affect the determination. That is, a determination may be solely based on specified factors or based on the specified factors as well as other, unspecified factors. Consider the phrase “determine A based on B.” This phrase specifies that B is a factor that is used to determine A or that affects the determination of A. This phrase does not foreclose that the determination of A may also be based on some other factor, such as C. This phrase is also intended to cover an embodiment in which A is determined based solely on B. As used herein, the phrase “based on” is synonymous with the phrase “based at least in part on.”

As used herein, the phrase “in response to” describes one or more factors that trigger an effect. This phrase does not foreclose the possibility that additional factors may affect or otherwise trigger the effect. That is, an effect may be solely in response to those factors or may be in response to the specified factors as well as other, unspecified factors. Consider the phrase “perform A in response to B.” This phrase specifies that B is a factor that triggers the performance of A. This phrase does not foreclose that performing A may also be in response to some other factor, such as C. This phrase is also intended to cover an embodiment in which A is performed solely in response to B.

As used herein, the terms “first,” “second,” etc. are used as labels for nouns that they precede and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.), unless stated otherwise. For example, in a register file having eight registers, the terms “first register” and “second register” can be used to refer to any two of the eight registers, and not, for example, just logical registers 0 and 1.

When used in the claims, the term “or” is used as an inclusive or and not as an exclusive or. For example, the phrase “at least one of x, y, or z” means any one of x, y, and z, as well as any combination thereof.

As used herein, a recitation of “and/or” with respect to two or more elements should be interpreted to mean only one element or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

The subject matter of the present disclosure is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” may be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.

Having thus described illustrative embodiments in detail, it will be apparent that modifications and variations are possible without departing from the scope of this disclosure as claimed. The scope of disclosed subject matter is not limited to the depicted embodiments but is rather set forth in the following Claims.