Method and apparatus for optimizing the cutting of raw boards into product boards

A method for optimizing the yield of a generally rectangular raw board, having a defects randomly located therein, into a number of product boards not having defects according to predetermined specifications, said number and specifications being stored in a manifest in an electronic computer means, and for minimizing waste in the operation of cutting said raw board, said manifest including a product board width which is the largest product board width and a product board width which is the smallest product board width of said manifest, comprising the steps of:

• determining a first line clear of defects as near as possible to a near edge of said raw board;
• determining a second line indicating the edge of a first defect nearest said first line, the distance between said first line and said second line determined to be a first clear width;
• determining a last line clear of defects on a far edge of said raw board, the distance between said first line and said last line determined to be a full width;
• transmitting said clear width and said full width to said electronic computer means;
• cutting off that portion of said raw board between said near edge and said first line as waste, while calculating an optimum solution for product boards to be cut from within said largest product board width, so as to result in the least amount of waste of said raw board;
• marking all defects within said largest product board width;
• cutting a sub-board from said raw board lengthwise, with the width thereof being determined according to the solution provided by said electronic computer means, leaving a remainder board;
• and
• thereafter cutting said sub-board transversely into at least one product board, thereby removing any waste therefrom, according to said solution.

A method for optimizing the yield of a generally rectangular raw board, having defects randomly located therein, into a predetermined number of product boards according to a predetermined specification, said predetermined number and specification being stored in a manifest in an electronic computer means, and for minimizing waste in the operation of cutting a raw board, said manifest including a product board width which is the largest product board width and a product board width which is the smallest product width of said manifest, said method comprising the steps of:

• determining a first line clear of defects as near as possible to a near edge of said raw board;
• determining a second line indicating the edge of the first defect nearest said first line, the distance between said first line and said second line determined to be the first clear width;
• determining a last line clear of defects on a far edge of said raw board, the distance between said first line and said last line determined to be the full width;
• transmitting said clear width and said full width to said electronic computer means;
• cutting off that portion of said raw board between said near edge and said first line as waste, while calculating an optimum solution for product boards to be cut from within said largest product board width, so as to result in the least amount of waste of said raw board;
• marking all defects from said first line to said largest product width;
• cutting a sub-board from said raw board lengthwise, with the width thereof being determined according to the solution provided by said electronic computer means, leaving a remainder board;
• and
• thereafter cutting said sub-board transversely into at least one product board, thereby removing any waste therefrom, according to said solution, while returning to said remainder board and determining on said remainder board a next line indicating the edge of the next defect nearest said second line on said remainder board, the distance between said second line and said next line being maximized and determined to be the next clear width;
• transmitting said next clear width to said electronic computer means and calculating an optimum solution for product boards to be cut from between said second line to said largest product board width, so as to result in the least amount of waste of said raw board;
• marking all defects from said second line to said largest product width;
• cutting a second sub-board from said remainder board lengthwise, with the width thereof being determined according to the solution provided by said electronic computer means, leaving a smaller remainder board;
• thereafter cutting said second sub-board transversely into at least one product board, thereby removing any waste therefrom, according to said solution;
• and
• continuing to perform said determining, transmitting, marking, lengthwise cutting and transversely cutting steps until said full width has been optimally and completely used to produce said product boards.

An apparatus for optimizing the yield from generally rectangular raw board, having defects randomly located therein, thereby cutting said raw board into an optimum number of various different product boards of predetermined specification and having no defects, comprising:

• first conveyor means for conveying said raw board along a first path to a first station;
• second conveyor means for transporting said raw board along a second path transverse to said first path and away from said first station;
• an adjustable fence located at said first station, oriented along said second path and movable transversely to said second path;
• temporary line-forming means located at said first station, for temporarily forming lines lengthwise on said raw board and transverse to said first path, and cooperating with said fence to determine a clear width and a full width of said raw board;
• means for detecting defects on said raw board between said lengthwise lines, and for indicating the location thereof of any of said defects therebetween;
• means for cutting said raw board lengthwise into a sub-board and a remainder board;
• electronic computer means for receiving said clear width and said full width from said fence and calculating an optimum solution as to the width and length of product boards to be cut, thereby determining the width of the sub-board and the length of the product boards to be cut from said sub-boards;
• means, located at a second station, for cutting said sub-board transversely into at least one product board;
• and
• third conveyor means for transporting said remainder board back to said first station.

A method for processing a generally rectangular raw board having defects randomly located therein so as to provide, with a minimum of waste, a plurality of product boards free of said defects and of predetermined lengths and widths, said method comprising the steps of:

• defining first and second waste areas lengthwise and along the near edge and the far edge, respectively, of said raw board;
• defining a first clear width lengthwise of said raw board and adjacent said first waste area;
• defining a full width lengthwise of said raw board and between said first and second waste areas;
• cutting said raw board lengthwise to remove said first waste area;
• performing calculations involving said full width, said first clear width and the location of defects within widest product board and further involving predetermined specifications as to the length and width of product boards to be produced to provide a cutting solution which will provide boards of predetermined width and length and free of defects with a minimum of waste;
• cutting said raw board lengthwise in accordance with said solution to remove said first clear width and thereby provide a sub-board and a remainder board;
• and cutting said sub-board transversely in accordance with said solution to provide at least one product board.