Multi-step systems for processing workpieces

Abstract

Systems, including method and apparatus, for processing workpieces driven automatically along a linear path to a plurality of positions disposed substantially along the linear path. In some embodiments, a workpiece may be processed at one or more of the positions using two or more processing stations, such as a first processing station that cuts the workpiece into segments and a second processing station that performs another processing operation on the workpiece.

1 . A method of constructing a face frame component for a cabinet comprising
 providing a cut list including dimensions of processed pieces required for construction of face frames for cabinets,   providing an apparatus configured to cut a work piece, to form a cavity in the work piece and to insert a joining member into the cavity in a single pass through the apparatus, and a computer connected to the apparatus configured to control movement and processing of the work piece, the apparatus having a linear processing path, a pusher configured for reciprocal movement along a length of the processing path to push a trailing end of an elongate work piece having a long axis parallel to the processing path, and a plurality of processing stations arranged along the processing path downstream from the pusher, a first station having a saw for cutting the work piece in a direction perpendicular to the processing path, a second station having equipment for forming a cavity in the work piece, and a third station having equipment for inserting a joining member into the cavity formed upstream at the first station,   programming the computer with an optimization program configured to calculate an optimum processing plan for a work piece based on a starting length of the work piece, and current requirements specified in the cut list stored in the computer,   entering the cut list into the computer,   providing a supply of work pieces for processing into dimensions specified in the cut list, each workpiece being preprocessed into a substantially straight form having a rectangular cross-section selecting a first work piece from the supply,   inputting data into the computer including the length of the first work piece,   calculating in the computer an optimum plan for processing the first work piece to satisfy current cut list requirements,   driving the pusher, under computer control, along a length of the processing path to push the trailing end of the first work piece down the processing path toward the processing stations,   cutting the first work piece, under computer control, perpendicular to the long axis of the first work piece at the first processing station, and   forming a cavity in the first work piece at a second processing station,   inserting a joining member in the cavity at the third processing station, and   assembling a joint between the first work piece and a second work piece via the joining member.   
   
   
       2 . The method of  claim 1 , wherein the joining member includes one of a dowel, biscuit, and butterfly lock. 
   
   
       3 . The method of  claim 1  further including the step of gluing the joining member into the cavity. 
   
   
       4 . The method of  claim 1 , wherein the assembling step is carried out by the apparatus. 
   
   
       5 . The method of  claim 1  further comprising the step of injecting glue into the cavity prior to the inserting step. 
   
   
       6 . The method of  claim 1  further comprising the step of coating an adhesive on the joining member prior to the inserting step. 
   
   
       7 . The method of  claim 1 , wherein the cavity and joining member have complimentary shapes. 
   
   
       8 . The method of  claim 1 , wherein the joining member fits into the cavity snugly. 
   
   
       9 . The method of  claim 1 , wherein the assembling step is performed off line from the apparatus. 
   
   
       10 . The method of  claim 1  further comprising
 inputting data into the computer indicating location of one or more defects including knots, cracks, or discoloration within the workpiece, wherein the calculating step includes calculating an optimum plan for processing the workpiece to satisfy current cut list requirements, and removing the one or more defects.   
   
   
       11 . The method of  claim 1 , wherein the first and second workpieces form a finger joint. 
   
   
       12 . The method of  claim 1 , wherein the first and second workpieces form a miter joint. 
   
   
       13 . The method of  claim 1 , wherein the first and second workpieces form a mortise and tenon joint. 
   
   
       14 . The method of  claim 1 , wherein the first and second workpieces form a dovetail joint. 
   
   
       15 . The method of  claim 1 , wherein the first and second workpieces form a dado joint. 
   
   
       16 . The method of  claim 1 , wherein the first and second workpieces form a lap joint. 
   
   
       17 . The method of  claim 1 , wherein the first and second workpieces form a splined joint. 
   
   
       18 . The method of  claim 1 , wherein the first and second workpieces form a tongue and groove joint.