Gauge system for workpiece processing

• US 8,783,140 B2
• Filed: 06/09/2010
• Issued: 07/22/2014
• Est. Priority Date: 06/09/2009
• Status: Active Grant

• Current Assignee: Lean Tool System, LLC
• Original Assignee: Lean Tool System, LLC
• Inventors: Dick, Spencer B., Aldrich, Stuart R., McClure, Brennan J., Lee, David L., Vaughn, Brandon J., Soot, Simon A., Gorny, Norman F., Harris, Matthew T., Gilmore, Richard R.
• Primary Examiner(s): NGUYEN, PHONG H
• Application Number:
  US12/797,581
• Publication Number:
  US 20110056344A1
• Time in Patent Office: 1,504 Days
• Field of Search: 83/13, 83/76, 83/761, 83 766- 769, 83/72, 833/91, 837/43, 837/45, 834/671, 83468-4687, 834/713, 835/81, 838/15, 838/16
• US Class Current: 83/13
• CPC Class Codes: B23D 45/14 for cutting otherwise than in a plane perpendicular to the axis of the stock, e.g. for making a mitred cut
• CPC Class Codes: B23D 47/025 of tables
• CPC Class Codes: B23D 59/001 Measuring or control devices, e.g. for automatic control of work feed pressure on band saw blade measuring in general G01; controlling in general G05
• CPC Class Codes: B27B 31/06 Adjusting equipment, e.g. using optical projection see also B27L5/022
• CPC Class Codes: G05B 19/18 Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form G05B19/418 takes precedence
• CPC Class Codes: G05B 19/402 characterised by control arrangements for positioning, e.g. centring a tool relative to a hole in the workpiece, additional detection means to correct position G05B19/19 takes precedence
• CPC Class Codes: G05B 2219/34286 Intelligent positioning I-O
• CPC Class Codes: Y10T 83/04 Processes
• CPC Class Codes: Y10T 83/148 Including means to correct the sensed operation
• CPC Class Codes: Y10T 83/162 With control means responsive to replaceable or selectable information program
• CPC Class Codes: Y10T 83/18 With operator input means
• CPC Class Codes: Y10T 83/5815 Work-stop abutment
• CPC Class Codes: Y10T 83/7593 Work-stop abutment

Abstract

Gauge system, including methods and apparatus, for positioning workpieces according to entered and/or calculated target dimensions and processing the workpieces with a tool to generate products having the target dimensions.

Claims

1. A method of preparing a workpiece for use in a miter joint, comprising:

mounting a saw to a stand, the saw defining a cutting path;

mounting a rail module to the stand, the rail module including a fence having opposite ends and extending parallel to a measurement axis that intersects the cutting path to define an origin, the rail module also including a stop movably connected or movably connectable to the fence;

mounting a motor box including a motor and a controller formed as a unit to the rail module, such that operation of the motor drives travel of the stop along the measurement axis to different separations from the origin, wherein the motor box is interchangeably mountable adjacent each opposite end of the fence to drive the stop;

entering into the controller a width and a target dimension of a product to be generated from a workpiece, the product having a miter at one or both ends;

commanding the controller to position the stop with compensation for the miter such that the controller controls operation of the motor based on the width and the target dimension to drive the stop to an adjusted position spaced from the origin according to an adjusted dimension that incorporates at least one miter offset into the target dimension; and

cutting the workpiece with the saw, while an end of the workpiece is disposed against the stop held at the adjusted position, to generate the product.

2. A method of preparing a workpiece for use in a miter joint, comprising:

mounting a saw to a stand, the saw defining a cutting path;

mounting a rail module to the stand, the rail module including a fence extending parallel to a measurement axis that intersects the cutting path to define an origin, the rail module also including a drive linkage disposed in and operatively connected to the fence and connected or connectable to a stop, the drive linkage including a first member;

mounting a motor box including a motor and a controller to the rail module, at least in part by moving the motor box as a unit downward along a vertical axis from a position over the fence and into engagement with the first member of the drive linkage while the first member remains rotatably connected to the fence, such that operation of the motor rotates the first member with respect to the fence, to drive the stop along the measurement axis to different separations from the origin, wherein the fence has opposite ends, and wherein the motor box is interchangeably mountable adjacent each opposite end of the fence to drive the stop;

entering into the controller a width and a target dimension of a product to be generated from a workpiece, the product having a miter at one or both ends;

commanding the controller to position the stop with compensation for the miter such that the controller controls operation of the motor based on the width and the target dimension to drive the stop to an adjusted position spaced from the origin according to an adjusted dimension that incorporates at least one miter offset into the target dimension; and

cutting the workpiece with the saw, while an end of the workpiece is disposed against the stop held at the adjusted position, to generate the product.

3. The method of claim 2, wherein the motor box includes a shaft turned by operation of the motor, and wherein the step of mounting a motor box includes a step of placing at least a portion of the shaft into an opening defined by the first member.

4. The method of claim 2, wherein the step of mounting a motor box includes a step of forming a splined connection between the first member and the motor box.

5. The method of claim 2, wherein the first member rotates about a vertical axis when the rail module is mounted to the stand, and wherein the step of mounting a motor box includes a step of moving the motor box downward along the vertical axis and into engagement with the first member.

6. The method of claim 2, wherein the motor box includes a shaft turned by operation of the motor, and wherein the step of mounting a motor box includes a step of placing at least a portion of the shaft into an opening defined by the first member on a top side of the rail module.

7. The method of claim 6, wherein the fence has a top wall, and wherein the step of placing includes a step of placing at least a portion of the shaft through the top wall of the fence.

8. A method of preparing a workpiece for use in a miter joint, comprising:

mounting a saw to a stand, the saw defining a cutting path;

mounting a rail module to the stand, the rail module including a fence extending parallel to a measurement axis that intersects the cutting path to define an origin, the rail module also including a drive linkage disposed in and operatively connected to the fence and connected or connectable to a stop;

mounting a motor to the fence, while the drive linkage remains operatively connected to the fence, such that operation of the motor moves the drive linkage with respect to the fence to drive the stop along the measurement axis to different separations from the origin, wherein the fence has opposite ends, and wherein the motor is interchangeably mountable adjacent each opposite end of the fence to drive the stop;

entering into a controller a width and a target dimension of a product to be generated from a workpiece, the product having a first mitered end opposite a second mitered end;

cutting the workpiece to form the first mitered end;

commanding the controller to position the stop such that the controller controls operation of the motor based on the width and the target dimension to drive the stop to an adjusted position spaced from the origin according to an adjusted dimension that incorporates at least one miter offset into the target dimension; and

cutting the workpiece again with the saw to form the second mitered end of the product, while the first mitered end of the workpiece is disposed against the stop held at the adjusted position.

9. The method of claim 8, further comprising a step of providing a piece of crown molding as a workpiece, wherein the crown molding has a spring angle formed between a wall and the crown molding when installed, and wherein the piece of crown molding is disposed at the spring angle but upside down during each step of cutting.

10. The method of claim 8, wherein the stop includes an engagement surface, further comprising a step of creating contact between the first mitered end and the engagement surface to define an axial position of the workpiece before the step of cutting the workpiece again.

11. The method of claim 8, further comprising a step of entering a width for the workpiece, wherein the step of commanding causes the controller to perform a step of determining the at least one miter offset based on the width.

12. The method of claim 11, further comprising a step of entering an angle related to at least one of the mitered ends, wherein the step of determining includes a step of determining the at least one miter offset based on the width and the angle.

13. The method of claim 12, wherein the step of determining includes a step of evaluating terms of respective Taylor polynomials generated from corresponding Taylor series for sine and cosine.

14. The method of claim 8, wherein the step of commanding includes a step of instructing the controller to perform a miter compensation and a step of instructing the controller to start movement of the stop.