Automated hardwood texturing system and associated methods

Patent metadata

Field	Value
Publication number	US-10071456-B2
Application number	US-201414216604-A
Country	US
Kind code	B2
Filing date	Mar 17, 2014
Priority date	Mar 15, 2013
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

Abstract

A system and method for imparting a textured surface effect in a board. The system and method are configured to releasably secure a charge on a table; determine a random abrasion pattern for the charge with at least one programmable controller; and control at least one abrasion assembly with the at least one programmable controller in accord with the random abrasion pattern to selectively engage and remove desired portions of the upper surface of the charge with the at least one abrasion assembly to form a randomized textured surface effect thereon.

First claim

What is claimed is:

1. A method, comprising:
releasably securing a charge on a table, wherein the charge has an upper surface and a longitudinal axis;
scanning the upper surface of the charge using a machine vision system to identify any defects present on the upper surface of the charge;
for each identified defect, defining a respective area of interest that bounds the identified defect;
creating a randomized textured surface effect for the charge based on a selected personality and any defined areas of interest with at least one programmable controller; and
controlling at least one abrasion assembly with the at least one programmable controller in accord with the randomized textured surface effect to selectively engage and remove desired portions of the upper surface of the charge with the at least one abrasion assembly to form the randomized textured surface effect in the upper surface of the charge,
wherein the randomized textured surface effect comprises a plurality of motion passes, each motion pass being oriented with respect to the longitudinal axis of the charge and a desired start location on the upper surface of the charge, wherein each motion pass comprises an approach segment, an abrasion segment, and an exit segment, and
wherein controlling the at least one abrasion assembly comprises monitoring and controlling an applied pressure of the at least one abrasion assembly on the upper surface of the charge throughout the abrasion segment of each motion pass.

2. The method of claim 1 , wherein the charge comprises at least one board.

3. The method of claim 2 , wherein the at least one board comprises a flooring board.

4. The method of claim 2 , wherein the at least one board comprises a wall board.

5. The method of claim 2 , wherein the charge comprises a plurality of boards, wherein each board has a longitudinal axis, and wherein the plurality of boards are positioned in adjoining relationship in which the longitudinal axis of each of the plurality of boards is positioned substantially parallel to the longitudinal axis of the charge.

6. The method of claim 1 , wherein the table is part of a shuttle assembly that moves the charge from a loading position to an abrasion position along a machine direction, and further comprising driving the table from the loading position to the abrasion position along the machine direction.

7. The method of claim 6 , further comprising utilizing a servo motor to drive the table of the shuttle assembly under control of the at least one programmable controller.

8. The method of claim 7 , wherein the servo motor drives the table of the shuttle assembly bi-axially.

9. The method of claim 6 , further comprising, prior to releasably securing the charge on the table, selectively positioning the charge to a predetermined position relative to both a center point of the table and the longitudinal axis of the table.

10. The method of claim 6 , wherein the table is substantially fixed in the abrasion position until the randomized textured surface effect is formed in the upper surface of the charge.

11. The method of claim 10 , wherein the table comprises a means for selectively adhering the charge to the table until the randomized textured surface effect is formed in the upper surface of the charge.

12. The method of claim 11 , wherein the means for selectively adhering the charge to the table comprises a charge supporting surface of the table having a plurality of openings disposed therein that are in communication with a vacuum source.

13. The method of claim 6 , wherein the charge comprises a plurality of boards, wherein each board of the plurality of boards has a pair of long side edge surfaces that further comprise a means for selectively connecting adjoining long side edges of adjacent boards.

14. The method of claim 1 , further comprising scanning the charge to determine the position of the charge on the table.

15. The method of claim 1 , wherein controlling the at least one abrasion assembly comprises controlling an approach angle of the at least one abrasion assembly relative to the upper surface of the charge during the approach segment and an elongate length of the approach segment.

16. The method of claim 1 , wherein controlling the at least one abrasion assembly comprises controlling an exit angle of the at least one abrasion assembly relative to the upper surface of the charge during the exit segment and an elongate length of the exit segment.

17. The method of claim 1 , wherein controlling the at least one abrasion assembly comprises controlling a yaw angle of the at least one abrasion assembly relative to the longitudinal axis of the charge during the abrasion segment.

18. The method of claim 1 , wherein each abrasion segment of each motion pass has a random start position and a median pass axis and further comprises a plurality of elongated axial abrasion sections, and wherein selected portions of each elongated axial abrasion section can be angled with respect to the longitudinal axis of the charge such that portions of each elongated axial abrasion section are offset from the median pass axis at a distance transverse to the median pass axis.

19. The method of claim 1 , wherein adjoining motion passes are offset from each other at a randomized distance.

20. The method of claim 1 , wherein at least a portion of adjoining motions passes overlap.

21. The method of claim 1 , wherein the at least one abrasion assembly is coupled to a tool assembly.

22. The method of claim 21 , further comprising utilizing a robotic action device under control of the programmable controller for selective multi-dimensional positioning of the tool assembly relative to the upper surface of the charge.

23. The method of claim 22 , wherein the at least one abrasion assembly is pivotally coupled to the tool assembly.

24. The method of claim 23 , further comprising utilizing a servo motor to pivotally rotate the at least one abrasion assembly relative to the tool assembly under control of the programmable controller.

25. The method of claim 24 , wherein the at least one abrasion assembly comprises at least one scraping blade.

26. The method of claim 25 , wherein the at least one scraping blade comprises a pair of spaced scraping blades.

27. The method of claim 26 , wherein the tool assembly comprises an elongate body pivotally rotatable about a center point, wherein a first scraping blade of the pair of spaced scraping blades is pivotally coupled to the tool assembly at a first end portion of the elongate body and wherein a second scraping blade of the pair of spaced scraping blades is pivotally coupled to the tool assembly at an opposed second end portion of the elongate body.

28. The method of claim 27 , further comprising utilizing a robotic action device under control of the programmable controller for selective multi-dimensional positioning of the tool assembly relative to the upper surface of the charge and for selective rotation of the tool assembly about the center point to selectively apply only one scraping blade of the pair of spaced scraping blades into programmed operative contact with the upper surface of the charge in a motion pass.

29. The method of claim 28 , wherein the randomized textured surface effect comprises a plurality of motion passes, each motion pass being oriented with respect to the longitudinal a

Assignees

• Columbia Insurance Co

Inventors

• Rees John J M
• Fernandez Conrad Layson
• Levan Eric John
• Milligan David Emmett
• Hixson Jr Leonard Lee
• Huitt Edward Keith
• Shelnutt Iii Robert Louis
• Voyles David Edward
• Espy Gregory Kevin
• Morris Roman

Classifications

• Y10T428/24438

  Artificial wood or leather grain surface · CPC title

• B24B7/28

  for grinding wood · CPC title

• B24B7/10 Primary

  Single-purpose machines or devices (grinding tools or machines specially designed for use on assembled railway track E01B31/17) · CPC title

• B44F9/02

  wood grain effects · CPC title

• B27M1/003

  Mechanical surface treatment · CPC title