Multi-step system 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 length dimensions and to rout a cavity in a work piece in a single pass through the apparatus, and a computer connected to the apparatus, 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, at least one of the stations including a saw orientated perpendicular to the processing path for cutting the work piece in a direction perpendicular to the long axis of the work piece, and at least one of the stations including a router bit configured to form a cavity in the work piece,   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 work piece, under computer control, perpendicular to the long axis of the first work piece at a first processing station, and   routing a cavity in the first work piece at a second processing station.   
   
   
       2 . The method of  claim 1 , wherein the cavity created by the routing step forms a mortise, further comprising the step of
 assembling a face frame component for a cabinet by forming a mortise and tenon joint between the first work piece and a second work piece.   
   
   
       3 . The method of  claim 1 , wherein the cavity created by the routing step forms a longitudinal groove, further comprising the step of
 inserting a spacer element in the groove.   
   
   
       4 . The method of  claim 3 , wherein the inserting step is performed by shooting the spacer element toward the groove. 
   
   
       5 . 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 work piece, 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.   
   
   
       6 . The method of  claim 4 , wherein the shooting step is carried out during the driving step. 
   
   
       7 . The method of  claim 3 , wherein the spacer element is oversized relative to a dimension of the groove. 
   
   
       8 . The method of  claim 3 , wherein the programming step includes programming the computer to determine which workpieces should include spacer elements. 
   
   
       9 . The method of  claim 3 , wherein the programming step includes programming the computer to determine a location for a spacer along a length of a workpiece. 
   
   
       10 . The method of  claim 1  further comprising the step of
 providing a marking station along the processing path of the apparatus, and   marking the first work piece at the marking station to indicate a position of attachment between a rail and a stile for a cabinet.   
   
   
       11 . The method of  claim 1  further comprising the step of
 providing a printing station along the processing path, and   printing a label for the first workpiece indicating a characteristic or future use for the workpiece.   
   
   
       12 . The method of  claim 11 , wherein the label is printed directly on the first workpiece.