MUNTIN BAR FABRICATION SYSTEM

• US 20170157786A1
• Filed: 12/07/2015
• Published: 06/08/2017
• Est. Priority Date: 12/07/2015
• Status: Active Grant

• Current Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Original Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Inventors: Knoble, Grant Michael, Hanzel, Joshua, Zehner, Kent
• Granted Patent: US 10,328,594 B2
• Time in Patent Office: Days
• CPC Class Codes: B23C 3/002 Milling elongated workpieces
• CPC Class Codes: B23K 2101/28 Beams
• CPC Class Codes: B23K 2103/05 Stainless steel
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 2103/36 Wood or similar materials
• CPC Class Codes: B23K 2103/42 Plastics B23K2103/16 takes precedence
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B23K 37/0235 the guide member forming part of a portal
• CPC Class Codes: B23K 37/04 for holding or positioning work
• CPC Class Codes: B23P 23/04 for both machining and other metal-working operations
• CPC Class Codes: B23Q 7/001 Lateral transport of long workpieces
• CPC Class Codes: B23Q 7/042 for the axial transport of long workpieces B23B13/022 takes precedence
• CPC Class Codes: B23Q 7/043 Construction of the grippers B23Q7/048 takes precedence
• CPC Class Codes: B23Q 7/06 by means of pushers B23Q7/1457, B23Q7/1489, B23B13/02, B23B13/12 take precedence
• CPC Class Codes: B23Q 7/10 by means of magazines
• CPC Class Codes: B23Q 7/141 with a series disposition of different working devices and with the axial transport for long workpieces of which a plurality of final products are made
• CPC Class Codes: B26D 11/00 Combinations of several similar cutting apparatus
• CPC Class Codes: B26D 2007/013 the work being tubes, rods or logs
• CPC Class Codes: B26D 5/005 Computer numerical control means
• CPC Class Codes: B26D 7/01 Means for holding or positioning work
• CPC Class Codes: B26D 7/0608 : by pushers B26D7/0616, B26D7/0625 and B26D7/0641 take precedence
• CPC Class Codes: B26D 7/0633 : by grippers
• CPC Class Codes: B26D 7/0641 : using chutes, hoppers, magazines
• CPC Class Codes: B26D 9/00 : Cutting apparatus combined with punching or perforating apparatus or with dissimilar cutting apparatus
• CPC Class Codes: B65G 47/901 : provided with drive systems with rectilinear movements only
• CPC Class Codes: E06B 3/685 : False glazing bars E06B3/6604 takes precedence
• CPC Class Codes: Y10T 29/5142 : and means to sever work from supply
• CPC Class Codes: Y10T 29/5145 : to sever product to length
• CPC Class Codes: Y10T 409/304536 : including means to infeed work to cutter
• CPC Class Codes: Y10T 83/647 : With means to convey work relative to tool station
• CPC Class Codes: Y10T 83/6476 : Including means to move work from one tool station to another
• CPC Class Codes: Y10T 83/6571 : With means to store work articles

Abstract

A muntin bar fabrication system can be used to efficiency produce a wide variety of different types of muntin bars, allowing the fabrication of both standard and custom muntin bar assemblies for doors, windows, and other fenestration products. In some examples, the fabrication system includes a muntin bar stock storage assembly that holds multiple different types of muntin bar stock. The system also includes a muntin bar stock extraction device that extracts one of the different types of muntin bar stock from the storage assembly and conveys the extracted muntin bar stock to a feed device. The feed device feeds the extracted piece of muntin bar stock into a cutting system that includes a multi-axis cutter. The cutting system that performs one or more cutting operations on the extracted muntin bar stock so as to fabricate one or more individual muntin bars from the extracted muntin bar stock.

Claims

1. A muntin bar fabrication system comprising:

a muntin bar stock storage assembly configured to receive and hold a plurality of different types of muntin bar stock;

a muntin bar stock extraction device configured to extract one of the plurality of different types of muntin bar stock from the muntin bar stock storage assembly and convey the extracted muntin bar stock to a muntin bar stock feed device; and

a cutting system comprising a multi-axis cutter, the cutting system being configured to receive the extracted muntin bar stock and perform one or more cutting operations on the extracted muntin bar stock so as to fabricate one or more individual muntin bars from the extracted muntin bar stock.

2. The system of claim 1,

wherein the muntin bar stock feed device is configured to advance a first end of the extracted muntin bar into the cutting system and the cutting system is configured to perform a first cutting operation on the first end of the extracted muntin bar, and

subsequent to performing the first cutting operation, the muntin bar stock feed device is configured to advance the extracted muntin bar further into the cutting system and the cutting system is configured to perform a second cutting operation on the extracted muntin bar stock to separate an individual muntin bar from a remainder of the extracted muntin bar stock.

3. The system of claim 1, wherein the one or more cutting operations comprise at least one of a transverse cut to separate an individual muntin bar from a remainder of the extracted muntin bar stock, a notch cut into the extracted muntin bar stock, and an angled cut to shape an end of the individual muntin bar.

4. The system of claim 1, wherein the cutting system further comprises a clamping device, and the cutting system is further configured to receive the extracted muntin bar stock, clamp the extracted muntin bar stock using the clamping device to provide a clamped section of extracted muntin bar stock, perform the one or more cutting operations on or adjacent the clamped section of extracted muntin bar stock, and subsequently release the clamped section of extracted muntin bar stock.

5. The cutting system of claim 4, wherein the clamping device comprises a first pair of jaws configured to clamp the extracted muntin bar stock in a generally horizontal direction and a second pair of jaws configured to clamp the extracted muntin bar stock in a generally vertical direction.

6. The system of claim 1, wherein the cutting system further comprises a plurality of punches, and wherein the cutting system is further configured to select a specific punch from the plurality of punches based on the type of muntin bar stock extracted from the plurality of different types of muntin bar stock and drive the punch into the extracted muntin bar stock.

7. The system of claim 6, wherein the plurality of punches comprise a first set of punches positioned at a location above where the extracted muntin bar stock is received by the cutting system and a second set of punches positioned at a location below where the extracted muntin bar stock is received by the cutting system.

8. The system of claim 1, wherein the multi-axis cutter comprises a three-axis rotary cutter.

9. The system of claim 8, wherein the cutting system holds a plurality of cutting heads and is configured to select a specific one of the plurality of cutting heads for use on the three-axis rotary cutter based on the type of muntin bar stock extracted from the plurality of different types of muntin bar stock.

10. The system of claim 1, wherein the muntin bar stock storage assembly comprises a first muntin bar stock storage assembly configured to receive individual pieces of muntin bar stock and a second muntin bar stock storage assembly configured to receive at least one container containing a plurality of pieces of muntin bar stock.

11. The system of claim 10, wherein the first muntin bar stock storage assembly comprises a loading hopper and a plurality of laterally spaced apart receiving cavities, wherein the loading hopper is configured to receive an individual piece of muntin bar stock by inserting the individual piece of muntin bar stock into the loading hopper, translate over to a selected one of the plurality of laterally spaced apart receiving cavities, and deposit the individual piece of muntin bar stock from the loading hopper into the select one of the plurality of laterally spaced apart receiving cavities.

12. The system of claim 11, further comprising a muntin bar pull mechanism configured to pull a piece of muntin bar stock out of one of the plurality of laterally spaced apart receiving cavities to expose the piece of muntin bar stock for extraction by the muntin bar stock extraction device.

13. The system of claim 1, wherein the muntin bar stock extraction device comprises an overhead pick and place assembly.

14. The system of claim 1, wherein the muntin bar stock feed device is positioned upstream of the cutting system, and further comprising a discharge table positioned downstream of the cutting system, the discharge table being configured to receive individual muntin bars discharged from the cutting system.

15. The system of claim 14, wherein the discharge table is configured to articulate between at least two positions relative to the cutting system including a first position in which the discharge table directs individual muntin bars discharged from the cutting system onto a work surface and a second position in which the discharge table directs pieces of muntin bar stock discharged from the cutting system to scrap.

16. The system of claim 1, further comprising a muntin bar stock reorientation device configured to grasp an end of the extracted muntin bar stock and rotate the extracted muntin bar stock 180 degrees relative to the cutting system.

17. The system of claim 1, wherein each of the plurality of different types of muntin bar stock comprise an elongated tubular member, and wherein at least one of the plurality of different types of muntin bar stock has at least one of a different size, a different shape, and a different color than at least one other of the plurality of different types of muntin bar stock.

18. A muntin bar fabrication system comprising:

a first muntin bar stock storage assembly having a plurality of laterally spaced apart receiving cavities configured to receive and hold different types of muntin bar stock;

a second muntin bar stock storage assembly configured to receive and hold at least one container containing a plurality of pieces of muntin bar stock in a vertically stacked arrangement;

a muntin bar pull mechanism configured to grasp a piece of muntin bar stock out of a select one of the plurality of laterally spaced apart receiving cavities of the first muntin bar stock storage assembly and pull the piece of muntin bar stock longitudinally out of the first muntin bar stock storage assembly;

a muntin bar stock extraction device configured to translate relative to the first muntin bar stock storage assembly and the second muntin bar stock storage assembly, vertically lower and grasp a piece of muntin bar stock pulled out of the first muntin bar storage assembly or a piece of muntin bar stock held in the at least one container of the second muntin bar stock storage assembly, vertically raise with a grasp piece of muntin bar stock, translate over to a muntin bar feed mechanism, and deposit the grasp piece of muntin bar on the muntin bar feed mechanism to provide an extracted muntin bar stock; and

a cutting system positioned downstream of the muntin bar feed mechanism, the cutting system being configured to receive the extracted muntin bar stock via the muntin bar feed mechanism and perform one or more cutting operations on the extracted muntin bar stock so as to fabricate one or more individual muntin bars from the extracted muntin bar stock.

19. The system of claim 18, wherein the cutting system comprises a multi-axis cutter, an array of punches, and a clamping device, and wherein the clamping device is positioned adjacent to the multi-axis cutter and the array of punches such that the clamping device is configured to clamp the extracted muntin bar stock in a fixed position while at least one of a selected punch of the array of punches is driven into the extracted muntin bar stock and the multi-axis cutter cuts the extracted muntin bar stock.

20. The system of claim 19, wherein the array of punches comprise a first set of punches positioned at a location above where the extracted muntin bar stock is received by the cutting system and a second set of punches positioned at a location below where the extracted muntin bar stock is received by the cutting system.

21. The system of claim 18, wherein the multi-axis cutter comprises a three-axis rotary cutter.

22. The system of claim 18, wherein the one or more cutting operations comprise at least one of a transverse cut to separate an individual muntin bar from a remainder of the muntin bar stock, a notch cut into the muntin bar stock, and an angled cut to shape an end of the individual muntin bar.

23. The system of claim 18, wherein the first muntin bar stock storage assembly further comprises a loading hopper and the loading hopper is configured to receive an individual piece of muntin bar stock by inserting the individual piece of muntin bar stock into the loading hopper, translate over to a selected one of the plurality of laterally spaced apart receiving cavities, and deposit the individual piece of muntin bar stock from the loading hopper into the select one of the plurality of laterally spaced apart receiving cavities.

24. The system of claim 18, wherein

the first muntin bar stock storage assembly is configured to receive an individual piece of muntin bar stock by inserting the individual piece of muntin bar stock longitudinally into one end of the first muntin bar stock storage assembly,

the muntin bar pull mechanism is configured to pull the piece of muntin bar stock longitudinally out of an opposite end of the first muntin bar stock storage assembly,

the muntin bar feed mechanism is configured to translate longitudinally in a direction parallel to a direction of travel of the muntin bar pull mechanism, and

the muntin bar stock extraction device is configured to translate laterally between the muntin bar pull mechanism and the muntin bar feed mechanism.

25. The system of claim 18, wherein the bar pull mechanism comprises a pair of fingers configured to move relative to each other to grasp the piece of muntin bar stock and a conveyor belt coupled to the pair of fingers and configured to move the pair of fingers longitudinally relative to the first muntin bar stock storage assembly.

26. The system of claim 18, wherein the muntin bar feed mechanism comprises a pushing member connected to a conveyor belt, the pushing member being configured to bear against a terminal end of the extracted muntin bar stock, the conveyor belt being configured to move the pushing member longitudinally relative to the cutting system.

27. The system of claim 18, wherein each of the different types of muntin bar stock and each of the plurality of pieces of muntin bar stock comprise an elongated tubular member, and wherein the first muntin bar storage assembly holds muntin bar stock having at least one of a different size, a different shape, and a different color than muntin bar stock held by the at least one container of the second muntin bar storage assembly.

28. A method comprising:

extracting one of a plurality of different types of muntin bar stock from a muntin bar stock storage assembly and conveying the extracted muntin bar stock to a muntin bar stock feed device;

depositing the extracted muntin bar stock on the muntin bar stock feed device;

feeding the extracted muntin bar stock into a cutting system via the muntin bar stock feed device; and

performing one or more cutting operations on the extracted muntin bar stock within the cutting system and thereby fabricating one or more individual muntin bars from the extracted muntin bar stock.

29. The method of claim 28, wherein performing one or more cutting operations on the extracted muntin bar stock comprises using a multi-axis rotor to at least one of cut the extracted muntin bar stock transversely to separate an individual muntin bar from a remainder of the extracted muntin bar stock, cutting a notch into the extracted muntin bar stock, the notch being configured to receive a joining key for joining different sections of muntin bar, and angle cutting to shape an end of the individual muntin bar.

30. The method of claim 28, further comprising selecting a punch from a plurality of different punches within the cutting system and driving the punch into the extracted muntin bar stock within the cutting system.

31. The method of claim 28, further comprising clamping the extracted muntin bar stock prior to performing the one or more cutting operations.

32. The method of claim 28, wherein extracting one of the plurality of different types of muntin bar stock from the muntin bar stock storage assembly comprises extracting one of the plurality of different types of muntin bar stock from a first muntin bar stock storage assembly loaded piece-by-piece with individual pieces of muntin bar stock and a second muntin bar stock storage assembly loaded with at least one container containing a plurality of pieces of muntin bar stock.

33. The method of claim 32, further comprising pulling a piece of muntin bar stock longitudinally out of the first muntin bar stock storage assembly prior to extracting one of the plurality of different types of muntin bar stock from the muntin bar stock storage assembly.

34. The method of claim 28, further comprising:

discharging the one or more individual muntin bars from the cutting system onto a work surface of a discharge table;

articulating the discharge table to a position in which the discharge table directs muntin bar stock discharged from the cutting system to scrap collection; and

discharging scrape muntin bar stock from the cutting system to scrap collection.

35. The method of claim 28, wherein each of the plurality of different types of muntin bar stock comprise an elongated tubular member, and wherein at least one of the plurality of different types of muntin bar stock has at least one of a different size, a different shape, and a different color than at least one other of the plurality of different types of muntin bar stock.