Patent ID: 12214521

Common reference numerals are used throughout the figures and the detailed description to indicate like elements. One skilled in the art will readily recognize that the above figures are merely illustrative examples and that other architectures, modes of operation, orders of operation, and elements/functions can be provided and implemented without departing from the characteristics and features of the invention, as set forth in the claims.

DETAILED DESCRIPTION

Embodiments will now be discussed with reference to the accompanying figures, which depict one or more exemplary embodiments. Embodiments may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein, shown in the figures, or described below. Rather, these exemplary embodiments are provided to allow a complete disclosure that conveys the principles of the invention, as set forth in the claims, to those of skill in the art.

The disclosed embodiments of methods and systems for layered wood product production include a local robotic panel assembly and pressing system. In one embodiment, the disclosed local robotic panel assembly and pressing system includes one or more local robotic panel assembly cells. In one embodiment, each local robotic panel assembly cell includes: one or more veneer handling robots; one or more glue application robots; and, in some embodiments, one or more core handling robots. According to the disclosed embodiments, the local robotic panel assembly cells are used to independently produce stacks of layered wood product panels at static positions at, or near, the pressing stations. Consequently, the disclosed local robotic panel assembly cells replace the prior art traditional panel conveyors, traditional layered wood product panel assembly layup lines, and stack press delivery lines discussed above with respect toFIGS.1A through1I. This, in turn, eliminates thousands of moving parts and dozens of people from the layered wood product production process. In addition, using the disclosed embodiments, hundreds of square feet of factory floor space traditionally used in the layered wood product production process are no longer required.

Consequently, using the disclosed embodiments, many of the shortcomings of prior art are minimized or by-passed/resolved. In addition, as discussed below, using the disclosed embodiments, not only are there significant cost savings in the layered wood product production process, but the resulting layered wood products produced using the disclosed embodiments are of a higher and more consistent quality.

FIG.2Ais a high-level diagram of a local robotic panel assembly and pressing station200A in accordance with one embodiment. As seen inFIG.2A, local robotic panel assembly and pressing station200A includes robot panel assembly cell201A that is used to create green panel stacks, such as green panel stack160A.

It is worth noting that green panel stack160A ofFIG.2Aproduced by robot panel assembly cell201A is virtually identical to green panel stack160A ofFIG.1G, or any of the green panel stacks160ofFIGS.1DorFIG.1G. Consequently, robot panel assembly cell201A literally replaces all of the prior art structure shown in asFIG.1Dand the stack production and processing section199ofFIG.1G, including traditional layered wood product panel assembly layup line150and stack press delivery line162. This alone means that local robotic panel assembly and pressing station200A eliminates the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators.

As also seen inFIG.2A, once robot panel assembly cell201A creates green panel stack160A, green panel stack160A is transferred to pre-press170A and green panel stack160A is loaded into pre-press170A where the green panel stack160A is subjected to cold pre-pressing in the same pre-pressing process as discussed above. In the press170A green panel stack160A is pressed to flatten out the structure and force out any air pockets that may exist in the green panel stack160A and to create pre-pressed stack161A.

Once pre-pressed stack161A is created, pre-pressed stack161A is conveyed to an unstacking mechanism (not shown) which feeds the layered wood structure panels making up pre-pressed stack161A one at a time into slots of hot press180A and is then subjected to hot pressing in the same pre-pressing process as discussed above. At hot press180A the layered wood structure panels making up pre-pressed stack161A are subjected to further pressure and heat to further flatten and cure the layered wood structure panels making up pre-pressed stack161A. The layered wood structure panels are then re-stacked to form cured layered wood panel product stack163A.

Cured layered wood panel product stack163A is then conveyed to panel trim, quality analysis, and shipping area111where the individual layered wood panels making up cured layered wood panel product stack163A are trimmed to size, subjected to quality control analysis, and then shipped to customers.

As noted, the pressing and trimming/quality control/shipping process shown inFIG.2Ais virtually identical to the pressing and finishing/quality control/shipping process discussed above with respect toFIG.1G. Thus, according to one embodiment, once robot panel assembly cell201A creates green panel stack160A, green panel stack160A is processed in the same manner, and using the same equipment, as is used to traditionally process layered wood products. Consequently, existing cold and hot press equipment need not be replaced. Therefore, the use of the disclosed local robotic panel assembly and pressing station200A results in eliminating the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators of the prior art structure shown in asFIG.1Dand the stack production and processing section199ofFIG.1G, while still minimizing the amount of processing equipment that must be replaced.

According to the disclosed embodiments, multiple local robotic panel assembly and pressing stations, such as local robotic panel assembly and pressing station200A, can be operated at once, and independently, to form a robotic panel assembly and pressing system220.

FIG.2Bis a diagram of a robotic panel assembly and pressing system220including four local robotic panel assembly and pressing stations200A through200D in accordance with one embodiment. In practice, the number of local robotic panel assembly and pressing stations can be fewer, or more, than the four shown inFIG.2B.

As seen inFIG.2B, each of local robotic panel assembly and pressing stations200A,200B,200C, and200D includes its own independently operating robot panel assembly cell201A,201B,201C, and201D, respectfully, that are used to independently create green panel stacks160A,160B,160C, and160D.

It is worth noting again that green panel stacks160A,160B,160C, and160D ofFIG.2Bproduced by local robot panel assembly cells201A,201B,201C, and201D are virtually identical to green panel stacks160A,160B,160C, and160D ofFIG.1G. Consequently, the set of local robot panel assembly cells201A,201B,201C, and201D literally replaces all of the prior art structure shown in asFIG.1Dand the stack production and processing section199ofFIG.1G, including traditional layered wood product panel assembly layup line150and stack press delivery line162. This alone means that the set of local robotic panel assembly and pressing stations200A,200B,200C, and200D eliminates the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators.

As also seen inFIG.2B, once local robot panel assembly cells201A,201B,201C, and201D create green panel stacks160A,160B,160C, and160D, green panel stacks160A,160B,160C, and160D are transferred to pre-presses170A,170B,170C, and170D, respectively, where the green panel stacks160A,160B,160C, and160D are subjected to cold pre-pressing. In the pre-presses170A,170B,170C, and170D, green panel stacks160A,160B,160C, and160D are pressed to flatten out the structures and force out any air pockets that may exist in the green panel stacks160A,160B,160C, and160D and to create pre-pressed stacks161A,161B,161C, and161D by the same pre-pressing process as discussed above.

Once pre-pressed stacks161A,161B,161C, and161D are created, pre-pressed stacks161A,161B,161C, and161D are conveyed into one or more unstacking mechanisms (not shown) which feed one layered wood structure panel at a time from the pre-pressed stacks161A,161B,161C, and161D into slots of one or more multi opening hot presses180A,180B.180C, and180D, respectively. At hot presses180A,180B,180C, and180D the layered wood structure panels making up pre-pressed stacks161A,161B,161C, and161D are subjected to further pressure and heat to further flatten and cure the layered wood structure panels making up pre-pressed stacks161A,161B,161C, and161D by the same hot pressing process as discussed above. Then the layered wood structure panels are re-stacked resulting in cured layered wood panel product stacks163A,163B,163C, and163D, respectively.

Cured layered wood panel product stacks163A,1634B,163C, and163D are then conveyed by conveyor299to panel trim, quality analysis, and shipping area111where the individual layered wood panels making up cured layered wood panel product stacks163A,1634B,163C, and163D are trimmed to size, subjected to quality control analysis, and then shipped to customers.

The pressing and trimming/quality control/shipping process shown inFIG.2Bis virtually identical to the pressing and finishing/quality control/shipping process discussed above with respect toFIG.1G. Thus, according to one embodiment, once robot panel assembly cells201A,201B,201C, and201D create green panel stacks160A,160B,160C, and160D, green panel stacks160A,160B,160C, and160D are processed by local robotic panel assembly and pressing stations200A through200D in the same manner, and using the same equipment, as used to traditionally process layered wood products. Consequently, existing cold and hot press equipment need not be replaced. Therefore, the use of the disclosed robotic panel assembly and pressing system220results in eliminating the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators of the prior art structure shown inFIG.1Dand the stack production and processing section199ofFIG.1G, while still minimizing the amount of processing equipment that must be replaced.

In addition, robotic panel assembly and pressing system220has several other processing advantages over prior art systems. First, recall that using prior systems such as that shown inFIG.1G, in addition to the cost of operating traditional layered wood product panel assembly layup and press line151, including stack production and processing section199, i.e., traditional layered wood product panel assembly layup line150and stack press delivery line162, there was a significant cost associated with any delays in traditional layered wood product panel assembly layup and press line151. These delays included delays due to failure of any of the thousands of moving parts associated with traditional layered wood product panel assembly layup and press line151, and particularly stack production and processing section199, or any human error introduced by the twelve or more people required to operate traditional layered wood product panel assembly layup and press line151.

Further recall that, referring toFIGS.1D and1Ftogether, when a delay occurred, for whatever reason, the layers of glue applied by glue applicators109A through109J could dry out before the green panel stacks160reached the pressing stations153through159. This, in turn, resulted in layered wood product panels that could separate or otherwise fail because the glue could not cure and adhere the layers properly. Unfortunately, this resulted in significant loss of product using traditional layered wood product panel assembly layup and press line151. Currently there is an average loss of product to defects of ten percent or more using traditional layered wood product panel assembly layup and press line151.

However, referring back toFIG.2B, in direct contrast to prior art systems, using independently operating robotic panel assembly and pressing system220, the green panel stacks160A,160B,160C, and160D are independently built at individual static locations at, or near, the pressing area by individual and independently operating robot panel assembly cells201A,201B,201C, and201D. Consequently, using robotic panel assembly and pressing system220if there is a delay in any of the local robotic panel assembly and pressing stations200A through200D, the delay only affects the panels being processed by that particular local robotic panel assembly and pressing station, i.e., only one of pressing stations200A through200D. As a result, any such delay can, at most, cause a single stack of panels to be lost. This is in direct contrast to the multiple stacks that can be lost as a result of delays in traditional layered wood product panel assembly layup and press line151. The product savings can literally be an order of magnitude or more as a delay in traditional layered wood product panel assembly layup and press line151can result in the loss of four hundred or more individual layered wood product panels while a delay in any of local robotic panel assembly and pressing stations200A through200D would typically result in, at most, forty individual layered wood product panels.

In addition, as noted above, using prior art methods and systems for producing layered wood products, such as using traditional layered wood product panel assembly layup and press line151, material and glue systems are configured to run a single product at a time, i.e., only a single ply count panel, or single type of product (plywood or PLV), at a time. Changing products required stopping the machine, removing all in process material, and then reconfiguring controls for new product construction.

However, and again in direct contrast to prior art systems, using robotic panel assembly and pressing system220, and local robotic panel assembly and pressing stations200A through200D, the green panel stacks160A,160B,160C, and160D are built independently at individual static locations at, or near, the pressing area by individual robot panel assembly cells201A,201B,201C, and201D. As a result, each of the local robotic panel assembly and pressing stations200A through200D can independently generate different products. Consequently, each of the local robotic panel assembly and pressing stations200A through200D can produce different ply count panels, or different types of products, plywood or PLV, independently and at the same time.

The fact that using robotic panel assembly, and pressing system220, local robotic panel assembly and pressing stations200A through200D, green panel stacks160A,160B,160C, and160D are built at independently operating individual static locations at or near the pressing area by individual robot panel assembly cells201A,201B,201C, and201D eliminates the issues discussed above associated with prior art systems where it was critical to ensure coordination between the stacker operator SO and each of the press operators PO1, PO2, PO3, and PO4ofFIG.1Gso that the wrong size stacks were not loaded into a pre-press or hot press that is unable to process them.

FIG.2Cis a more detailed diagram of a robotic panel assembly cell201A ofFIGS.2A and2Bin accordance with one embodiment.

Robotic panel assembly cell201A is exemplary of any of the individual robot panel assembly cells201A,201B,201C, and201D ofFIGS.2A and2B. As seen inFIG.2C, robotic panel assembly cell201A is used to create green panel stack160A which is itself exemplary of any of the green panel stacks160A,160B,160C, and160D ofFIGS.2A and2B.

As seen inFIG.2C, robotic panel assembly cell201A includes veneer handling robot251which is representative of one or more veneer handling robots; glue application robot255which is representative of one or more glue application robots; and, in some embodiments where plywood green layered wood product panel stacks are to be produced, core handling robot253which is representative of one or more core handling robots.

Also seen inFIG.2Cis control system202which is used to control veneer handling robot251, core handling robot253, and glue application robot255. In various embodiments, control system202is representative of one or more computing systems which generate instructions for veneer handling robot251, core handling robot253, and glue application robot255in the form of control signals. In this way, control system202directs veneer handling robot251, core handling robot253, and glue application robot255in the construction of the green panel stack160A via the generated control signals.

In one embodiment, veneer handling robot251is directed by the control signals from control system202to retrieve veneer sheets from veneer stack103A and place the veneer sheets on green plywood panel stack160A in accordance with received control signals to create the green layered wood product panels241and243in green panel stack160A as discussed above and as shown inFIG.2C.

In one embodiment, glue application robot255is directed by the control signals from control system202to apply a layer of glue from glue reservoir256between sheets of veneer and/or core material in accordance with received control signals to create the green layered wood product panels241and243in green panel stack160A as discussed above and as shown inFIG.2C.

In embodiments where robotic panel assembly cell201A is used to create green plywood panels241and a green plywood panel stack160A, robotic panel assembly cell201A includes core handling robot253. In one embodiment, core handling robot253is directed by the control signals from control system202to retrieve core material from core stack113A and place a portion of core material on green plywood panel stack160A in accordance with received control signals to create the green plywood panels241and243in green plywood panel stack160A as discussed above and as shown inFIG.2C.

Robots, such as veneer handling robot251, glue application robot255, and core handling robot253are generally known in the art, at least generically as systems for handling materials and performing various tasks in response to control signals from one or more control systems. Consequently, a detailed description of the general structure and operation of robots is omitted here to avoid detracting from the invention. However, the tasks performed by veneer handling robot251, glue application robot255, and core handling robot253and the use of veneer handling robot251, glue application robot255, and core handling robot253to produce green layered wood panel stacks, such as green panel stack160A are not known in the art and therefore the functions performed by veneer handling robot251, glue application robot255, and core handling robot253are described in detail.

In particular, as shown inFIG.2C, veneer handling robot251is first directed by control signals from control system202to retrieve veneer sheet271from the stack of veneer sheets103A and place the veneer sheet271on green panel stack160A.

Then glue application robot255is directed by the control signals from control system202to apply a layer of glue281from glue reservoir256to veneer sheet271.

In embodiments where robotic panel assembly cell201A is used to create green plywood panels, then core handling robot253is directed by the control signals from control system202to retrieve core material from core stack113A and place a portion of core material on green panel stack160A to create core layer291.

Glue application robot255is then directed by the control signals from control system202to apply a layer of glue283from glue reservoir256on core layer291. Then veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet273from the stack of veneer sheets103A and place the veneer sheet273on green layered wood product panel160A.

Of note, in embodiments where robotic panel assembly cell201A is used to produce green layered wood product stacks of other types of layered wood products, such as green PLV panels, core handling robot253is either deactivated or not present. In these cases, veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet271from the stack of veneer sheets103A and place the veneer sheet271on green panel stack160A. Then glue application robot255is directed by the control signals from control system202to apply a layer of glue281from glue reservoir256to veneer sheet271. Then veneer handling robot251is simply directed by control signals from control system202to retrieve another veneer sheet273from the stack of veneer sheets103A and place the veneer sheet273on veneer sheet271.

The result of the operations above is a three-ply green layered wood product panel241. As noted above, plywood, and other layered wood product panels often have twenty-one or more plys. However, for simplicity of illustration, green layered wood product panel241is a three-ply green layered wood product panel241.

Once green layered wood product panel241is constructed by robotic panel assembly cell201A, robotic panel assembly cell201A begins to construct a second green layered wood product panel243of green panel stack160A. To this end, veneer handling robot251is again directed by control signals from control system202to retrieve a veneer sheet275from the stack of veneer sheets103A and place the veneer sheet275on the glue-free side of veneer sheet273. Importantly, veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet275from the stack of veneer sheets103A and place the veneer sheet275on the veneer sheet273directly, without any glue layer being applied by glue application robot255. This creates a dry veneer to veneer layer, or gap240. Gap240therefore separates green layered wood product panel241and green layered wood product panel243in green panel stack160A.

Then glue application robot255is directed by the control signals from control system202to apply a layer of glue285from glue reservoir256to veneer sheet275. In embodiments where robotic panel assembly cell201A is used to create green plywood panels, then core handling robot253is directed by the control signals from control system202to retrieve core material from core stack113A and place a portion of core material on green panel stack160A to create core layer293. Then glue application robot255is directed by the control signals from control system202to apply a layer of glue287from glue reservoir256on core layer293Then veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet277from the stack of veneer sheets103A and place the veneer sheet277on green panel stack160A.

Of note again, in embodiments where robotic panel assembly cell201A is used to produce green layered wood product stacks of other types of layered wood products, such as green PLV panels, core handling robot253is either deactivated or not present. In these cases, veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet275from the stack of veneer sheets103A and place the veneer sheet275on green panel stack160A. Then glue application robot255is directed by the control signals from control system202to apply a layer of glue285from glue reservoir256to veneer sheet275. Then veneer handling robot251is simply directed by control signals from control system202to retrieve another veneer sheet277from the stack of veneer sheets103A and place the veneer sheet277on veneer sheet275.

The result of the operations above is a second three-ply green layered wood product panel243. The process above is then repeated to create the desired number of green layered wood product panels for green panel stack160A. As noted above, it is not uncommon for green panel stack160A to include forty or more individual green layered wood product panels.

It is worth noting again that green panel stack160A ofFIG.2Cproduced by robot panel assembly cell201A is virtually identical to green panel stack160A ofFIG.1G, or any of the green panel stacks160ofFIGS.1DorFIG.1G. Consequently, robot panel assembly cell201A literally replaces all of the prior art structure shown inFIG.1Dand the stack production and processing section199ofFIG.1G, including traditional layered wood product panel assembly layup line150and stack press delivery line162. This alone means that local robotic panel assembly and pressing station200A eliminates the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators.

In addition, according to the disclosed embodiments, and in contrast to prior art systems, robot panel assembly cell201A is located locally at, or near, pre-press170A and hot press180A. Therefore, green panel stack160A is assembled by robot panel assembly cell201A locally with respect to the pressing line. Consequently, robot panel assembly cell201A assembles the same green panel stack160A as any of the green panel stacks160ofFIGS.1DorFIG.1Glocally with respect to pre-press170A and hot press180A and at a single location.

As seen inFIG.2A, once robot panel assembly cell201A creates green panel stack160A, green panel stack160A is transferred to pre-press170A and green panel stack160A is loaded into pre-press170A where the green panel stack160A is subjected to cold pre-pressing. In the pre-press170A green panel stack160A is pressed to flatten out the structure and force out any air pockets that may exist in the green panel stack160A and to create pre-pressed stack161A.

Once pre-pressed stack161A is created, pre-pressed stack161A is conveyed to an unstacking mechanism (not shown) which feeds the layered wood structure panels making up pre-pressed stack161A one at a time into slots of hot press180A. At hot press180A the layered wood structure panels making up pre-pressed stack161A are subjected to further pressure and heat to further flatten and cure the layered wood structure panels making up pre-pressed stack161A. The layered wood structure panels are then re-stacked to form cured layered wood panel product stack163A.

Cured layered wood panel product stack163A is then conveyed to panel trim, quality analysis, and shipping area111where the individual layered wood panels making up cured layered wood panel product stack163A are trimmed to size, subjected to quality control analysis, and then shipped to customers.

In one embodiment, the pressing and trimming/quality control/shipping process shown inFIG.2Ais virtually identical to the pressing and finishing/quality control/shipping process discussed above with respect toFIG.1G. Thus, according to one embodiment, once robot panel assembly cell201A creates green panel stack160A, green panel stack160A is processed in the same manner, and using the same equipment, as is used to traditionally process layered wood products. Consequently, existing cold and hot press equipment need not be replaced. Therefore, the use of the disclosed local robotic panel assembly and pressing station200A results in eliminating the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators of the prior art structure shown in asFIG.1Dand the stack production and processing section199ofFIG.1G, while still minimizing the amount of processing equipment that must be replaced.

As discussed briefly above, the same layering of veneer that potentially provides so many advantages in layered wood products can also present some drawbacks. For instance, the presence of irregular surfaces in the layered sheets of veneer, i.e., inconsistent surface texture and moisture content, can create problems, such as cracks or other defects, in the layered wood products. This, of course, can result in compromised structural integrity of the layered wood products and/or undesirable imperfections in the layered wood products. Consequently, it is critical to accurately and efficiently determine the surface texture and moisture content of the veneer sheets used in a layered wood products. However, accurately, effectively, and efficiently determining the surface texture and moisture content of the veneer sheets used in layered wood products has historically been a difficult technical problem to solve.

Consequently, prior art methods and systems for producing layered wood products typically do not include any process for inspecting or grading veneer sheets used in the production of layered wood products. As a result, using prior art methods and systems for producing layered wood products, the quality of veneer fed into process was not inspected during feeding operation. Therefore, undetected defects often caused panels to be rejected only downstream after significant time and energy had already been devoted to the panels, i.e., pressing is complete and panel quality is analyzed.

Several recently discovered technical solutions to the technical problem of accurately and efficiently determining the surface texture and moisture content of the veneer sheets used in a layered wood products are set forth in the related U.S. Patent Applications incorporated by reference above. Using these disclosed quality inspection methods and systems, the surface texture and moisture of veneer sheets used in layered wood products can be determined before the veneer is processed.

In one embodiment, the disclosed method and system for producing layered wood products takes advantage of these innovations to inspect and grade the veneer sheets used in the disclosed method and system for producing layered wood products. To this end, in one embodiment, the disclosed local robotic panel assembly and pressing stations include a veneer inspection/grading robot and an inspection/grading system which is used to determine the quality of veneer fed into process during feeding operation. Therefore, defects can be detected, and the veneer sheets can be graded before significant time and energy has already been devoted to the panels.

FIG.2Dis a diagram of a local robot panel assembly cell211A that is similar to robot panel assembly cell201A ofFIGS.2A,2B, and2Cbut that includes a veneer inspection and grading system204and multiple graded veneer stacks206,208,210and212in accordance with one embodiment.

The operation of local robot panel assembly cell211A is substantially similar to the operation of robot panel assembly cell201A ofFIGS.2A,2B, and2C. However, before veneer sheets from veneer stack103A are made available to veneer handling robot251the veneer sheets are retrieved by veneer inspection/grading robot245which is representative of one or more veneer inspection/grading robots. Veneer inspection/grading robot245then presents each veneer sheet to the veneer inspection/grading system204in accordance with control signals from control system202.

At the veneer inspection/grading system204the veneer sheets are inspected and assigned a grade based on the inspection results. Veneer inspection/grading system204can utilize one or more inspection methods and systems such as any of those set forth in the related U.S. Patent Applications incorporated by reference above. For example, Veneer inspection/grading system204can utilize one of more visible light inspection systems and/or one or more Near Infrared (NIR) inspection systems and/or superimposed imaging to detect surface irregularities, moisture levels, density, and to assign a grade to the veneer sheets of veneer stack103A.

In one embodiment, based on the grade assigned to each veneer sheet, each veneer sheet is placed in one of graded veneer stacks, such as graded veneer stacks206,208,210and212ofFIG.2Dby veneer inspection/grading robot245. In one embodiment, veneer stack206is a grade 1 veneer stack that includes veneer sheets that are deemed to be of acceptable appearance and quality to be used for outer veneer layers of a layered wood panel. In one embodiment, veneer stack208is a grade 2 veneer stack that includes veneer sheets that are deemed to be of acceptable structural quality to be used for inner veneer layers of a layered wood panel but perhaps lack the appearance to be used as outer layers of a layered wood panel. In one embodiment, veneer stack210is a grade 3 veneer stack that includes veneer sheets that are deemed to have structural anomalies, such as knot holes, and therefore must be sparingly used for inner veneer layers of a layered wood panel and perhaps must be sandwiched between higher grade veneer sheets to provide adequate structural quality for the layered wood panel. Finally, in one embodiment, trash212contains veneer sheets of unacceptable quality.

By grading veneer sheets from veneer stack103A and stacking the veneer sheets according to grade, the quality of veneer fed into process during feeding operation is determined before resources are expended processing the veneer, i.e., defects can be detected in the veneer sheets, and the veneer sheets can be graded, and allocated for their best use, before significant time and energy is devoted to their use in processed panels.

Once the veneer sheets from veneer stack103A are inspected/graded by inspection grading system204, and the sheets are placed in appropriate graded veneer stacks206,208,210and212by veneer inspection/grading robot245, robot panel assembly cell211A operates the same way as robot panel assembly cell201A ofFIGS.2A,2B, and2C.

In particular, as shown inFIG.2D, veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet271from the appropriate graded veneer stack206,208,210and place the veneer sheet271on green panel stack160A.

Then glue application robot255is directed by the control signals from control system202to apply a layer of glue281from glue reservoir256to veneer sheet271.

In embodiments where robotic panel assembly cell211A is used to create green plywood panels, then core handling robot253is directed by the control signals from control system202to retrieve core material from core stack113A and place a portion of core material on green panel stack160A to create core layer291.

Glue application robot255is then directed by the control signals from control system202to apply a layer of glue283from glue reservoir256on core layer291. Then veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet273from the appropriate graded veneer stack206,208,210and place the veneer sheet273on green layered wood product panel160A.

Of note, in embodiments where robotic panel assembly cell211A is used to produce green layered wood product stacks of other types of layered wood products, such as green PLV panels, core handling robot253is either deactivated or not present. In these cases, veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet271from the appropriate graded veneer stack206,208,210and place the veneer sheet271on green panel stack160A. Then glue application robot255is directed by the control signals from control system202to apply a layer of glue281from glue reservoir256to veneer sheet271. Then veneer handling robot251is simply directed by control signals from control system202to retrieve another veneer sheet273from the appropriate graded veneer stack206,208,210and place the veneer sheet273on veneer sheet271.

The result of the operations above is a single three-ply green layered wood product panel241. As noted above, plywood, and other layered wood product panels often have twenty-one or more plys. However, for simplicity of illustration, green layered wood product panel241is a single three-ply green layered wood product panel241.

Once green layered wood product panel241is constructed by robotic panel assembly cell211A, robotic panel assembly cell211A begins to construct a second green layered wood product panel243of green panel stack160A. To this end, veneer handling robot251is again directed by control signals from control system202to retrieve veneer sheet275from the appropriate graded veneer stack206,208,210and place the veneer sheet275on the glue-free side of veneer sheet273. Importantly, veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet275from the appropriate graded veneer stack206,208,210and place the veneer sheet275on the veneer sheet273directly, without any glue layer being applied by glue application robot255. This creates a dry veneer to veneer layer, or gap240. Gap240therefore separates green layered wood product panel241and green layered wood product panel243in green panel stack160A.

Then glue application robot255is directed by the control signals from control system202to apply a layer of glue285from glue reservoir256to veneer sheet275. In embodiments where robotic panel assembly cell211A is used to create green plywood panels, then core handling robot253is directed by the control signals from control system202to retrieve core material from core stack113A and place a portion of core material on green panel stack160A to create core layer293. Then glue application robot255is directed by the control signals from control system202to apply a layer of glue287from glue reservoir256on core layer293Then veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet277from the appropriate graded veneer stack206,208,210and place the veneer sheet277on green panel stack160A.

Of note again, in embodiments where robotic panel assembly cell211A is used to produce green layered wood product stacks of other types of layered wood products, such as green PLV panels, core handling robot253is either deactivated or not present. In these cases, veneer handling robot251is directed by control signals from control system202to retrieve veneer sheet275from the appropriate graded veneer stack206,208,210and place the veneer sheet275on green panel stack160A. Then glue application robot255is directed by the control signals from control system202to apply a layer of glue285from glue reservoir256to veneer sheet275. Then veneer handling robot251is simply directed by control signals from control system202to retrieve another veneer sheet277from the appropriate graded veneer stack206,208,210and place the veneer sheet277on veneer sheet275.

The result of the operations above is a second single three-ply green layered wood product panel243. The process above is then repeated to create the desired number of green layered wood product panel for green panel stack160A. As noted above, it is not uncommon for green panel stack160A to include forty or more individual green layered wood product panels.

It is worth noting again that green panel stack160A ofFIG.2Dproduced by robot panel assembly cell211A is virtually identical to green panel stack160A ofFIG.1G, or any of the green panel stacks160ofFIG.1DorFIG.1G. Consequently, robot panel assembly cell211A literally replaces all of the prior art structure shown in asFIG.1Dand the stack production and processing section199ofFIG.1G, including traditional layered wood product panel assembly layup line150and stack press delivery line162. This alone means that local robotic panel assembly and pressing station200A eliminates the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators.

In addition, according to the disclosed embodiments, and in contrast to prior art systems, robot panel assembly cell211A is located locally at, or near, pre-press170A and hot press180A. Therefore, green panel stack160A is assembled by robot panel assembly cell211A locally with respect to the pressing line. Consequently, robot panel assembly cell211A assembles the same green panel stack160A as any of the green panel stacks160ofFIGS.1DorFIG.1Glocally with respect to pre-press170A and hot press180A and at a single location.

As seen inFIG.2D, once robot panel assembly cell211A creates green panel stack160A, green panel stack160A is transferred to pre-press170A and green panel stack160A is loaded into pre-press170A where the green panel stack160A is subjected to pre-pressing by the methods discussed above. In the cold press170A green panel stack160A is pressed to flatten out the structure and force out any air pockets that may exist in the green panel stack160A and to create pre-pressed stack161A.

Once pre-pressed stack161A is created, pre-pressed stack161A is conveyed to an unstacking mechanism (not shown) which feeds the layered wood structure panels making up pre-pressed stack161A one at a time into slots of hot press180A. At hot press180A the layered wood structure panels making up pre-pressed stack161A are subjected to further pressure and heat to further flatten and cure the layered wood structure panels making up pre-pressed stack161A by the methods discussed above. The layered wood structure panels are then re-stacked to form cured layered wood panel product stack163A.

Cured layered wood panel product stack163A is then conveyed to panel trim, quality analysis, and shipping area111where the individual layered wood panels making up cured layered wood panel product stack163A are trimmed to size, subjected to quality control analysis, and then shipped to customers.

The pressing and trimming/quality control/shipping process shown inFIG.2Dis virtually identical to the pressing and finishing/quality control/shipping process discussed above with respect toFIG.1G. Thus, according to one embodiment, once robot panel assembly cell211A creates green panel stack160A, green panel stack160A is processed in the same manner, and using the same equipment, as is used to traditionally process layered wood products. Consequently, existing cold and hot press equipment need not be replaced. Therefore, the use of the disclosed local robotic panel assembly and pressing station200A results in eliminating the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators of the prior art structure shown in asFIG.1Dand the stack production and processing section199ofFIG.1G, while still minimizing the amount of processing equipment that must be replaced.

In some embodiments, a quality analysis and feedback cell for process refinement is included in a local robot panel assembly cell.FIG.3is a diagram of a local robotic panel assembly and pressing station300including a quality analysis and feedback cell301for process refinement in accordance with one embodiment.

As seen inFIG.3, once local robot panel assembly cell201A creates green panel stack160A, green panel stack160A is transferred to pre-press170A and green panel stack160A is loaded into pre-press170A where the green panel stack160A is subjected to cold pre-pressing. In the pre-press170A green panel stack160A is pressed to flatten out the structure and force our any air pockets that may exist in the green panel stack160A and to create pre-pressed stack161A by the methods discussed above.

Once pre-pressed stack161A is created, pre-pressed stack161A is conveyed to an unstacking mechanism (not shown) which feeds the layered wood structure panels making up pre-pressed stack161A one at a time into slots of hot press180A. At hot press180A the layered wood structure panels making up pre-pressed stack161A are subjected to further pressure and heat to further flatten and cure the layered wood structure panels making up pre-pressed stack161A by the methods discussed above. The layered wood structure panels are then re-stacked to form cured layered wood panel product stack163A.

Cured layered wood panel product stack163A is then conveyed to panel trim, quality analysis, and shipping area111where the individual layered wood panels making up cured layered wood panel product stack163A are trimmed to size, subjected to quality control analysis, and then shipped to customers.

FIG.4Ais a photograph of one type of wood product panel bond analyzer401used in accordance with one embodiment. In one embodiment, wood product panel bond analyzer401is included as part of panel trim, quality analysis, and shipping area111.

As seen inFIG.4A, in one embodiment, wood product panel bond analyzer401includes an array of ultrasonic transmitter/receiver pairs403and405(not visible inFIG.4A) that send a pulse through the wood panel product. The amplitude of the signal passed through the wood by transmitters403and received by receivers405, and the time delay between the transmissions from transmitters403to the receipt of those transmissions by receivers405are recorded and these parameters are utilized to calculate the quality of bond of the wood panel.

FIG.4Bis a photograph of a structural density analysis report411based on the results of processing using one type of wood product panel bond analyzer used in accordance with one embodiment.

As seen inFIG.4B, in one embodiment, the wood panel exits the press and typically passes through the wood product panel bond analyzer401ofFIG.4A. Typically wood product panel bond analyzer401is configured to analyze and record the reading for each 3″×3″ square of the panel as it passes the ultrasonic heads. This size can be configured per customer requirements, with 3″ being common in wood products panel manufacturing. For each panel analyzed, the grader prepares a data file and represents it in a visual format. The top image413is typically gray scale and the lower image411being colorized. The customer can define the values required for quality and alert if those thresholds are not met. Numerous combinations of quality and number of adjacent squares can be considered per customer requirements.

FIG.4Cis a photograph of average panel thickness analysis report421based on the results of processing using one type of wood product panel bond analyzer used in accordance with one embodiment.

FIG.4Dis a photograph of panel thickness trend analysis report423based on the results of processing using one type of wood product panel bond analyzer used in accordance with one embodiment.

Referring toFIGS.4C and4Dtogether, typically each panel is also measured for thickness. Alert points can be configured as to allow alerting when thresholds are exceeded. Panel thickness is often controlled by press pressure and/or press to position instrumentation allowing the press to compress the panel the required amount to produce a completed panel withing selected tolerances.

The pressing and trimming/quality control/shipping process shown inFIG.3is virtually identical to the pressing and finishing/quality control/shipping process discussed above with respect toFIG.1G. Thus, according to one embodiment, once robot panel assembly cell201A creates green panel stack160A, green panel stack160A is processed in the same manner, and using the same equipment, as is used to traditionally process layered wood products. Consequently, existing cold and hot press equipment need not be replaced. Therefore, the use of the disclosed local robotic panel assembly and pressing station200A results in eliminating the need for hundreds of square feet of floor space, thousands of moving parts, multiple sensors and motors, and dozens of sub-assemblies and human operators of the prior art structure shown in asFIG.1Dand the stack production and processing section199ofFIG.1G, while still minimizing the amount of processing equipment that must be replaced.

Referring toFIGS.2C and3together, when the individual layered wood panels making up cured layered wood panel product stack163A are subjected to quality control analysis at panel trim, quality analysis, and shipping area111, quality parameter data, such as, but not limited to, the data discussed above with respect toFIGS.4A,4B,4C, and4D, regarding each layered wood panel making up cured layered wood panel product stack163A is collected.

In various embodiments, this quality parameter data represents results from analysis of specific quality parameters and specific quality parameter values, such as density and thickness as discussed above.

In one embodiment, the specific quality parameters and specific quality parameter values of the quality parameter data obtained from the quality control analysis at panel trim, quality analysis and shipping area111is correlated with control signal and production parameter data obtained from control system202of robot panel assembly cell201A. In one embodiment, the quality parameter data and control signal and production parameter data are forwarded to quality analysis and feedback cell301for analyzing the quality of cured layered wood product panels. Based on this analysis, the control signals sent from control system202of robot panel assembly cell201A to the one or more veneer handling robots, the one or more core handling robots, and the one or more glue application robots is adjusted in order to improve the quality of subsequent cured layered wood product panels.

In one embodiment, the quality analysis and feedback cell301includes an artificial intelligence module (not shown). In one embodiment, the quality analysis and feedback cell301obtains the quality parameter data from the quality analysis of multiple cured layered wood product panels and correlates the quality parameter data associated with each cured layered wood product panel and the control signal and production parameter data associated with the control signals generated by control system202used to control the one or more veneer handling robots, the one or more glue application robots, and the one or more core handling robots used to produce the cured layered wood product panel.

In one embodiment, the correlated quality data and control signal and production parameter data is then used as training data to generate a trained artificial intelligence module. In one embodiment, the trained artificial intelligence module is then used adjust the control signals used to control the one or more veneer handling robots, the one or more glue application robots, and the one or more core handling robots automatically for subsequent green layered wood product panel stack production.

Embodiments of the present disclosure provide an effective and efficient technical solution to the long-standing technical problem of providing a method and system for producing layered wood products that is less expensive to operate and more efficient than prior art methods.

In one embodiment, local robotic panel assembly cells including: one or more veneer handling robots; one or more glue application robots; and, in some embodiments, one or more core handling robots, are used to independently produce stacks of layered wood product panels at or near the pressing stations. The local robotic panel assembly cells are used to assemble the stacks at independent static locations local to the pressing stations and as the stacks are required. Consequently, using the disclosed embodiments, the stacks of layered wood product panels are independently built locally at the pressing stations thereby eliminating the need for traditional panel conveyors, traditional layered wood product panel assembly layup lines, and stack press delivery lines. This, in turn, eliminates thousands of moving parts and dozens of people from the layered wood product production process.

The disclosed methods and systems include one or more independently operating local robotic panel assembly and pressing stations that include: a robot panel assembly cell, the robot panel assembly cell producing a stack of green layered wood product panels; a pre-press, the pre-press pressing the stack of green layered wood product panels to produce pre-pressed layered wood product panels; and a hot press, the hot press heating and pressing the pre-pressed layered wood product panels to produce cured layered wood product panels.

In one embodiment, the robot panel assembly cell includes: one or more veneer handling robots, the one or more veneer handling robots retrieving veneer sheets from a stack of veneer sheets and placing the veneer sheets on a green layered wood product panel stack in accordance with received control signals; one or more glue application robots, the one or more glue application robots applying a layer of glue between sheets of veneer in the green layered wood product panel stack in accordance with received control signals; and a control system for controlling the one or more veneer handling robots and the one or more glue application robots and directing the one or more veneer handling robots and the one or more glue application robots in the construction of the green layered wood product panel stack via control signals sent to the one or more veneer handling robots and the one or more glue application robots.

In one embodiment, the robot panel assembly cell includes: one or more veneer handling robots, the one or more veneer handling robots retrieving veneer sheets from a stack of veneer sheets and placing the veneer sheets on a green plywood panel stack in accordance with received control signals; one or more core handling robots, the one or more core handling robots retrieving core material from a core material stack and placing the core material on the green plywood panel stack in accordance with received control signals; one or more glue application robots, one or more glue application robots applying a layer of glue between sheets of veneer and core material in the green plywood panel stack in accordance with received control signals; and a control system for controlling the one or more veneer handling robots, the one or more core handling robots, and the one or more glue application robots and directing the one or more veneer handling robots, the one or more core handling robots, and the one or more glue application robots in the construction of the green plywood panel stack via control signals sent to the one or more veneer handling robots, the one or more core handling robots, and the one or more glue application robots.

In one embodiment, the robot panel assembly cell includes: one or more veneer handling robots, the one or more veneer handling robots retrieving veneer sheets from a stack of veneer sheets and placing the veneer sheets on a green PLV panel stack in accordance with received control signals; one or more glue application robots, the one or more glue application robots applying a layer of glue between sheets of veneer in the green PLV panel stack in accordance with received control signals; and a control system for controlling the one or more veneer handling robots and the one or more glue application robots and directing the one or more veneer handling robots and the one or more glue application robots in the construction of the green PLV panel stack via control signals sent to the one or more veneer handling robots and the one or more glue application robots.

Consequently, using the disclosed embodiments, many of the shortcomings of prior art are minimized or by-passed/resolved. For instance, using the methods and systems for producing layered wood products disclosed herein there is the no need for traditional panel conveyors, traditional layered wood product panel assembly layup lines, nor stack press delivery lines. Therefore, the large physical size, e.g., hundreds of feet, of factory floor space required by prior art methods and systems are not needed.

In addition, since using the methods and systems for producing layered wood products disclosed herein there is no need for traditional panel conveyors, traditional layered wood product panel assembly layup lines, nor stack press delivery lines, the thousands of moving parts and sensors required by prior art methods and systems are no longer required nor utilized. This makes the disclosed methods and systems for producing layered wood products much less maintenance intensive.

In addition, since using the methods and systems for producing layered wood products disclosed herein there is no need for traditional panel conveyors, traditional layered wood product panel assembly layup lines, nor stack press delivery lines, there is no need for the large number of electric motors and substantial power consumption required by prior art methods and systems. This makes the disclosed methods and systems for producing layered wood products less expensive to operate and a less of a drain on the environment.

In addition, since using the methods and systems for producing layered wood products disclosed herein there is no need for traditional panel conveyors, traditional layered wood product panel assembly layup lines, nor stack press delivery lines, the disclosed methods and systems are less manpower intensive for operation and maintenance. This makes the disclosed methods and systems for producing layered wood products not only less expensive to operate but also less subject to human error and potential injury.

In addition, unlike prior art methods and systems, any failure of any one of the substantially fewer moving parts required by the disclosed methods and systems for producing layered wood products, or any human error introduced, does not result in substantial product waste due to glue degradation, i.e., glue dry out. This is because using the methods and systems for producing layered wood products disclosed herein the stacks of layered wood product panels are independently built locally at the pressing stations so there is, at most, only one stack that may be lost if there is a failure in the associated pressing station. This means a loss of, at most, forty layered wood product panels, as compared to a potential loss of four hundred or more panels using prior art methods and systems.

In addition, unlike prior art methods and systems, using the methods and systems for producing layered wood products disclosed herein material and glue systems can be configured to run multiple products at a time, i.e., multiple ply count panel products and/or multiple types of product (plywood or PLV), at a time. This is because using the methods and systems for producing layered wood products disclosed herein the stacks of layered wood product panels are independently built at the pressing stations. Consequently, each pressing station has its own robot panel assembly cell and each robot panel assembly cell can be directed/controlled by control signals to independently assemble a different product.

In addition, unlike prior art methods and systems, using the methods and systems for producing layered wood products disclosed herein glue application robots are used to assemble each stack. These glue application robots apply the glue by moving back and forth over the structure, as opposed to having the structure move beneath the glue applicator. Consequently, glue spread rates can be very precisely controlled and it is relatively simple to make fine adjustments to the amount of glue applied to compensate for ambient temperature, line speed changes, etc.

In addition, unlike prior art methods and systems, using the methods and systems for producing layered wood products disclosed herein the robot panel assembly cells and control systems can be used to make a direct correlation between individual panel quality and the assembly process variables used for construction of that specific panel.

In addition, since using the methods and systems for producing layered wood products disclosed herein there is no need for traditional panel conveyors, traditional layered wood product panel assembly layup lines, nor stack press delivery lines, housekeeping, i.e., keeping the workplace clean and safe, is a much simpler since the assembly locations are static and of relatively small physical size. In addition, since using the methods and systems for producing layered wood products disclosed herein each robot panel assembly cell can operate a local robot panel assembly and pressing line completely independently of other local robot panel assembly and pressing lines, when keep up is required at one local robot panel assembly and pressing line only that local robot panel assembly and pressing line need to shut down while the other local robot panel assembly and pressing lines continue to operate.

In addition, in one embodiment, the disclosed method and system for producing layered wood products includes a veneer inspection/grading robot and an inspection/grading system which is used to determine the quality of veneer fed into process during feeding operation. Therefore, defects can be detected, and the veneer sheets can be graded before significant time and energy has already been devoted to the panels.

The present invention has been described in particular detail with respect to specific possible embodiments. Those of skill in the art will appreciate that the invention may be practiced in other embodiments. For example, the nomenclature used for components, capitalization of component designations and terms, the attributes, data structures, or any other programming or structural aspect is not significant, mandatory, or limiting, and the mechanisms that implement the invention or its features can have various different names, formats, or protocols. Further, the system or functionality of the invention may be implemented via various combinations of software and hardware, as described, or entirely in hardware elements. Also, particular divisions of functionality between the various components described herein are merely exemplary, and not mandatory or significant. Consequently, functions performed by a single component may, in other embodiments, be performed by multiple components, and functions performed by multiple components may, in other embodiments, be performed by a single component.

In addition, the operations shown in the figures, or as discussed herein, are identified using a particular nomenclature for ease of description and understanding, but other nomenclature is often used in the art to identify equivalent operations.

Therefore, numerous variations, whether explicitly provided for by the specification or implied by the specification or not, may be implemented by one of skill in the art in view of this disclosure.