Field of Invention

The invention generally relates to an edge modification method and apparatus, and in particular although not solely to an edge modification method and apparatus for applying an edge tape or band to furniture component or panels or other objects.

Background to the Invention

It is known to apply edging around the perimeter of tables or other panels or objects used in the construction of furniture. Such edging, whether wood veneer, plastic, melamine or high pressure laminate, affords furniture such as table tops a degree of durability and wear resistance that would otherwise be non-existent if no edging were to be applied. It also enhances the appearance of such objects. It is common for edging to be applied continuously using a variety of different techniques which vary in their complexity, cost, and reliability.

Hand lay-up techniques are most common but usually demand a certain amount of skill on the part of the operator. Such techniques have the disadvantage of creating variability in the final product as the degree of adhesion is reliant upon the pressing force applied to the edging during deposition as well as the orientation of the force in relation to the edge of the object. Hand laying techniques are also labour intensive and can be expensive for large volume work.

Alternative techniques rely upon modern CNC (Computer Numerical Control) of a presser head. CNC machines rely on pre-programmed information on the shape of the object to follow its contour and simultaneously apply the tape. Such systems tend to be costly and slow, with machining of the edge necessary prior to the application of the edging, in order to ensure the path the machine follows is commensurate with the object. Other edge modification machines use sensors or sensing mechanisms that precede a tape applying assembly. The tape applying assembly generally includes a tape laying assembly that lays edge tape on or along the edge and also includes some type of pressure applying mechanism. One example of a pressure applying mechanism is a roller that applies pressure to push the edging tape against the edge of a panel or an object.

US7,243,696 discloses an edge modification apparatus that includes a contact roller that follows the contour of an edge or a panel or other object, a force applicator that applies a vectored force to press the roller onto the edge of the panel. The apparatus also includes an edge sensor that determines the slope of the profile of the edge or at least determines a shape of the edge using suitable techniques. One example edge sensor disclosed in US7,243,696 comprises two rollers one trailing and one advanced roller that are engaged together via a linkage. A disadvantage of this system is that the use of two rollers, leading and trailing the pressure roller can create problems with accuracy of the force vector the pressure is applied at. In particular due to the spacing of the two sensing rollers, the true radial angle (i.e. the normal force vector) of a central pressure roller is not represented. Hence, the radial angle (i.e. the force vector) of the pressure roller can often become advanced or retarded in respect to the true normal.

W02019/035017 discloses an improved edge modification apparatus that addresses the above- mentioned disadvantage of an inaccurately calculated force vector, by implementing a control method to determine the force vector from a single roller. However, such a system, and other known systems, requires skilled manual input to trim edge banding at corners of the object, or more complex set up to ensure banding is trimmed accurately at the ends of an edge of the panel or object.

Disadvantages of known systems are complexity, the effort needed to load and setup a system, including the requirement for pre-programming of controllers with a shape of a panel that is being edge banded. Systems are therefore expensive to set up and operate and require expert technicians to service and setup/program the systems adding a further expensive labour cost. Each new shaped panel or object has to be pre-programmed thereby making the systems expensive to use and limiting the speed at which panels of varying shapes can be processed.

All references, including any patents or patent applications cited in this specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

Summary of the Invention

It is an object of the invention to provide an edge modification apparatus and related method that goes at least some way to addressing one or more of the above-mentioned disadvantages, or to at least provide the public with a useful choice.

According to a first aspect of the invention, an edge modification apparatus is provided to modify an edge of an object. The object has a first edge and an adjacent second edge, each extending from a corner of the object. The apparatus comprises: a fixed structure to which the object is mounted; a chassis movable relative to the fixed structure; a roller mounted to the chassis to contact an edge of the object; a motor to drive rotation of the roller to traverse the roller along the edge of the object and move the chassis relative to the fixed structure and the object; a force application arrangement to drive the chassis to apply a force to the edge of the object via the roller as the roller traverses along the edge of the object; a tool assembly for performing an edge modification operation at the corner of the object, the tool movable relative to the fixed structure; a drive mechanism to move the tool assembly relative to the fixed structure and object; a controller; a sensing arrangement in communication with the controller to detect a position of the roller in a coordinate system of the apparatus as the roller traverses along the edge of the object; at least one edge sensor in communication with the controller to detect an edge of the object; the edge sensor mounted to the chassis in a fixed relation to the roller; wherein the controller is configured to: cause the roller to move towards the corner of the object in a direction along (aligned with) a lead portion or end portion of the first edge; determine a corner position in the coordinate system for the corner of the object or a corner offset position in the coordinate system, wherein the corner offset position is a point on the second edge of the object offset from the corner of the object, and wherein the controller determines the corner position or corner offset position based on detection of the second edge by the edge sensor and the position of the roller, and cause the tool assembly to move to the corner of the object and perform an edge modification operation at the corner of the object, wherein the controller positions the tool assembly at the corner of the object by locating the tool assembly to the corner position or corner offset position.

In some embodiments, the controller determines the corner position, or the offset corner position, based on the position of the roller when the edge sensor detects the second edge and a known offset between the edge sensor and the roller.

In some embodiments, the controller determines the corner position, or the offset corner position, based on an angle of the corner of the object.

In some embodiments, the controller tracks the position of the roller as the chassis moves relative to the fixed structure and the object.

In some embodiments, the controller determines a trajectory of the roller as the roller moves towards the corner and determines the corner position, or the offset corner position, based on the trajectory.

In some embodiments, the controller determines an angle of the trajectory of the roller in the coordinate system and determines the corner position or corner offset position based on the angle of the trajectory.

In some embodiments, the controller determines the corner position, or the offset corner position, based on an angle of the first and/or second edges in the coordinate system. In some embodiments, the controller causes rotation of the roller to move the roller towards the corner of the object.

In some embodiments, the apparatus comprises a lead block removably attachable to the fixed structure to be aligned with the lead portion of the first edge of the object; and wherein the controller drives the roller along an edge of the lead block aligned with the lead portion of the first edge towards the corner of the object at the lead portion of the first edge.

In some embodiments, the apparatus comprises an end block removably attachable to the fixed structure to be aligned with the end portion of the first edge of the object; and wherein the controller drives the roller along the first edge of the object towards the corner of the object at the end portion of the object and onto the end block.

In some embodiments, the apparatus comprises a chassis drive to orientate the chassis in a desired orientation relative to the first edge of the object, and the controller is configured to cause the chassis to be orientated in the desired orientation as the roller moves towards the corner of the object.

In some embodiments, the chassis drive rotates the chassis on a rotational axis of the roller and the controller is configured to cause the chassis to rotate on the rotational axis of the roller to orientate the chassis in the desired orientation.

In some embodiments, the chassis is oriented in the desired orientation relative to the first edge of the object to achieve a known angle between the first edge of the object and a line extending through the edge sensor and the rotational axis of the roller.

In some embodiments, the chassis is oriented in the desired orientation to position the edge sensor in a known position relative to the roller and the first edge of the object. In some embodiments, the drive mechanism is configurable as the force application arrangement to drive the chassis to apply a force to the edge of the object via the roller as the roller traverses along the edge of the object.

In some embodiments, the drive mechanism is configurable to move the chassis relative to the fixed structure.

In some embodiments, the apparatus comprises a first motor and a second motor, in a positional control mode, the first and second motors are configured as the drive mechanism, to drive the chassis and the tool assembly relative to the fixed structure and object, and in a torque control mode, the first and second motors are configured as the force application arrangement to drive the chassis to apply a force to the edge of the object via the roller as the roller traverses along the edge of the object.

In some embodiments, the tool assembly comprises a tool head with a tool bit and a mechanism to move the tool head between a parked position and an operational position, in the parked position the tool assembly is clear of the chassis during movement of the chassis relative to the fixed structure and object, in the operation position the tool head is positioned at a known offset from the roller, and wherein the controller is configured to: cause the chassis to move, to move the roller away from the edge of the object; cause the tool head to move from the parked position to the operational position, and cause the tool assembly to move to the corner of the object and perform the edge modification operation at the corner of the object.

In some embodiments, the tool assembly comprises: a tool head with a tool bit, an actuator to rotate the tool bit about a vertical axis to achieve a desired angular orientation relative to the first edge, and wherein the controller is configured to: cause rotation of the tool bit about the vertical axis to position the tool bit in a desired angular orientation relative to the first edge of the object to perform the edge modification operation at the corner of the object.

In some embodiments, the apparatus comprises a chassis drive to orientate the chassis in a desired orientation relative to the first edge of the object, and a chassis orientation sensor in communication with the controller, and wherein the controller is configured to determine the desired angular orientation of the tool bit based on the desired orientation of the chassis.

In some embodiments, the controller determines the desired angular orientation of the tool bit based on an angle of the corner of the object.

In some embodiments, the tool assembly comprises a tool edge sensor to detect an edge of the object, and wherein the controller positions the tool assembly at the corner of the object to align the tool edge sensor with the corner offset position or the second edge adjacent the corner.

In some embodiments, the tool edge sensor is aligned with the vertical axis.

In some embodiments, the tool head is movable in a vertical direction and the tool bit and tool edge sensor are movable between an aligned position and an offset position, in the aligned position the tool edge sensor is aligned with the vertical axis, in the offset position the tool bit and tool edge sensor are moved to position the tool edge sensor to be offset to a side of the vertical axis, and wherein the controller is configured to: cause the tool bit and tool edge sensor to move from the aligned position to the offset position, cause the tool head to move vertically to place the tool edge sensor adjacent the second edge of the object, cause the tool bit and tool edge sensor to move from the offset position to the aligned position to contact the second edge of the object.

In some embodiments, the tool assembly comprises: a tool head with a tool bit; a tool edge sensor to detect an edge of the object; and wherein the controller causes the tool assembly to move to the corner of the object to align the tool edge sensor with the corner offset position.

In some embodiments, the tool head is movable in a vertical direction and the tool bit and tool edge sensor are movable between an aligned position and an offset position, wherein the controller is configured to: cause the tool assembly to move to the corner of the object to align the tool edge sensor with the corner offset position with the tool bit and tool edge sensor in the aligned position, cause the tool bit and tool head edge sensor to move from the aligned position to the offset position to be offset from the second edge of the object, cause the tool head to move vertically to place the tool edge sensor adjacent the second edge of the object, cause the tool bit and tool head edge sensor to move from the offset position to the aligned position to contact the second edge of the object.

In some embodiments, with the tool edge sensor in contact with the second edge the controller is configured to cause the tool head to move vertically to move the tool bit from above the object to below the object to perform the edge modification operation at the corner of the object. In some embodiments, the tool assembly comprises a tool head with a tool bit, and wherein the tool head is movable in a vertical direction to move the tool bit from above the object to below the object, and wherein the controller is configured to cause the tool head to move vertically to move the tool bit from above the object to below the object to perform the edge modification operation at the corner of the object.

In some embodiments, the apparatus is adapted to provide an edge tape to the edge of the object and the roller is a pressure roller to apply pressure to the edge of the object to adhere the edge tape to the edge of the object.

In some embodiments the apparatus applies the edge tape to overhang ends of the first edge of the object, and wherein the tool assembly is a trimmer assembly and the edge modification operation at the corner of the object is a cutting operation to trim an overhanging portion of the tape flush with the corner of the object.

According to a second aspect of the invention, a method for modifying an edge of an object is provided. The object has a first edge and an adjacent second edge, each extending from a corner of the object. The method comprises: moving a roller towards the corner of the object in a direction along a lead portion or end portion of the first edge; determining a corner position in a coordinate system for the corner of the object or a corner offset position in the coordinate system, wherein the corner offset position is a point on the second edge of the object offset from the corner of the object, wherein determination of the corner position or corner offset position is based on detection of the second edge by an edge sensor and the position of the roller, and moving a tool assembly for performing an edge modification operation at the corner of the object to the corner and positioning the tool assembly at the corner of the object by locating the tool assembly to the corner position or the corner offset position, and performing an edge modification operation at the corner of the object with the tool assembly.

In some embodiments, the method comprises determining the corner position, or the offset corner position, based on the position of the roller when the edge sensor detects the second edge and a known offset between the edge sensor and the roller.

In some embodiments, the method comprises determining the corner position, or the offset corner position, based on an angle of the corner of the object.

In some embodiments, the method comprises determining a trajectory of the roller as the roller moves towards the corner and determining the corner position, or the offset corner position, based on the trajectory.

In some embodiments, the method comprises determining an angle of the trajectory of the roller in the coordinate system and determining the corner position or corner offset position based on the angle of the trajectory.

In some embodiments, the method comprises determining the corner position, or the offset corner position, based on an angle of the first and/or second edges in the coordinate system.

In some embodiments, the method comprising rotating the roller to move the roller towards the corner of the object.

In some embodiments, the method comprises aligning a lead block with the lead portion of the first edge of the object; and driving the roller along an edge of the lead block aligned with the lead portion of the first edge towards the corner of the object at the lead portion of the first edge. In some embodiments, the method comprises aligning an end block with the end portion of the first edge of the object; and driving the roller along the first edge of the object towards the corner of the object at the end portion of the object and onto the end block.

In some embodiments, the roller and edge sensor are carried on a chassis and the method comprises orientating the chassis in a desired orientation relative to the first edge of the object as the roller moves towards the corner of the object.

In some embodiments, the method comprises rotating the chassis on a rotational axis of the roller to orientate the chassis in the desired orientation.

In some embodiments, the method comprises orienting the chassis in the desired orientation relative to the first edge of the object to achieve a known angle between the first edge of the object and a line extending through the edge sensor and the rotational axis of the roller.

In some embodiments, the method comprises orienting the chassis in the desired orientation to position the edge sensor in a known position relative to the roller and the first edge of the object.

In some embodiments, the method comprises: configuring a drive mechanism as a force application arrangement to drive the chassis to apply a force to the edge of the object via the roller as the roller traverses along the edge of the object, and configuring the drive mechanism to move the tool assembly to the corner.

In some embodiments, the method comprises configuring the drive mechanism to move the roller relative to the object away from an edge of the object.

In some embodiments, the method comprises: configuring a first motor and a second motor in a positional control mode, to drive the chassis and the tool assembly relative to the object, and configuring the first and second motors in a torque control mode to drive the chassis to apply a force to the edge of the object via the roller as the roller traverses along the edge of the object.

In some embodiments, the tool assembly comprises a tool head with a tool bit, the method comprising: positioning the tool head in a parked position to be clear of a chassis carrying the roller during movement of roller relative to the object, moving the chassis to move the roller away from the edge of the object; moving the tool head from the parked position to the operational position, and moving the tool assembly to the corner of the object and performing the edge modification operation at the corner of the object.

In some embodiments, the tool assembly comprises a tool head with a tool bit, and an actuator to rotate the tool bit about a vertical axis, and wherein the method comprises rotating the tool bit about the vertical axis to position the tool bit in a desired angular orientation relative to the first edge of the object to perform the edge modification operation at the corner of the object.

In some embodiments, the method comprises determining the desired angular orientation of the tool bit based on the desired orientation of the chassis.

In some embodiments, the method comprises determining the desired angular orientation of the tool bit based on an angle of the corner of the object.

In some embodiments, the tool assembly comprises a tool edge sensor to detect an edge of the object, and wherein the method comprises positioning the tool assembly at the corner of the object to align the tool edge sensor with the corner offset position or the second edge adjacent the corner. In some embodiments, the tool head is movable in a vertical direction and the tool bit and tool edge sensor are movable between an aligned position in which the tool edge sensor is aligned with the vertical axis and an offset position in which the tool bit and the edge sensor are moved to position the tool edge sensor to be offset to a side of the vertical axis, wherein the method comprises: moving the tool bit and tool edge sensor from the aligned position to the offset position, moving the tool head vertically to place the tool edge sensor adjacent the second edge of the object, moving the tool bit and tool edge sensor from the offset position to the aligned position to contact the second edge of the object.

In some embodiments, the tool assembly comprises a tool head with a tool bit and a tool edge sensor to detect an edge of the object; and wherein the method comprises moving the tool assembly to the corner of the object to align the tool edge sensor with the corner offset position.

In some embodiments, the tool head is movable in a vertical direction and the tool bit and tool edge sensor are movable between an aligned position and an offset position, and wherein the method comprises: moving the tool assembly to the corner of the object to align the tool edge sensor with the corner offset position with the tool bit and tool edge sensor in the aligned position, moving the tool bit and tool head edge sensor from the aligned position to the offset position to be offset from the second edge of the object, moving the tool head vertically to place the tool edge sensor adjacent the second edge of the object, moving the tool bit and tool head edge sensor from the offset position to the aligned position to contact the second edge of the object. In some embodiments, with the tool edge sensor in contact with the second edge the method comprises moving the tool head to move vertically to move the tool bit from above the object to below the object to perform the edge modification operation at the corner of the object.

In some embodiments, the tool assembly comprises a tool head with a tool bit, and wherein the tool head is movable in a vertical direction to move the tool bit from above the object to below the object, the method comprising: moving the tool head vertically to move the tool bit from above the object to below the object to perform the edge modification operation at the corner of the object.

In some embodiments, the roller is a pressure roller and the method comprises providing an edge tape to the edge of the object and applying pressure to the edge of the object with the pressure roller to adhere the edge tape to the edge of the object.

In some embodiments, the tool assembly is a trimmer assembly and the edge modification operation at the corner of the object is a cutting operation to trim an overhanging portion of the tape flush with the corner of the object.

The second aspect of the invention may include providing components or features of an apparatus as described above for the first aspect of the invention.

In this specification and claims, the edge of the object may be the edge of the object with or without an edge band applied.

In this specification and claims, unless the context suggests otherwise, the term "tool bit" should be interpreted generally to mean a part or component used to perform an edge modification operation on the edge of the object, and including but not limited to a cutting tool or bit, a rotary tool bit such as a drill bit, router bit or other rotary cutting tool, a paint applicator, a grinder or sanding tool, and a manipulator for placing a component to the edge of the object. Throughout this specification and claims, the word "comprise", or variations thereof such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Brief Description of the Drawings

Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which:

Figure 1 shows an embodiment of an edge modification apparatus in accordance with the present invention.

Figure 2 shows a bed of the apparatus of Figure 1 with supports for supporting an object in an operational position on the bed.

Figure 3 shows a chassis of the apparatus of Figure 1 and various components carried by the chassis.

Figure 4 shows a roller carried by the chassis spaced from a lead block prior at the beginning of an edge modification process.

Figure 5 shows the roller carried by the chassis in contact with the lead block.

Figure 6 shows the roller at or adjacent a lead portion of a first edge of the object and an edge sensor of the apparatus detecting a second edge of the object.

Figure 7 shows the roller at or adjacent an end portion of the first edge of the object and an edge sensor of the apparatus detecting a 'second' second edge of the object. Figure 8 shows the edge tape applied to the edge of the object with end portions of the tape overhanging the edge onto the lead and end blocks.

Figure 9 is schematic representation of the lead block and the object with the roller moved in alignment with the first edge along the lead block. Figure 10 is a schematic representation of the lead block and the object with the roller moved in alignment with the first edge along the lead block towards the corner of the object with a corner angle greater than 90 degrees.

Figure 11 shows a tool (trimmer) assembly in a parked position. Figure 12 shows the tool (trimmer) assembly in an operational position. Figure IB shows the chassis with roller at the beginning of an edge modification operation with the tool assembly in a parked position.

Figure 14 shows the chassis with roller at the end of an edge modification operation with the tool assembly in a parked position. Figure 15 shows the chassis with roller moved away from the edge of the object and with the tool assembly in a parked position.

Figure 16 shows the chassis and the tool assembly in an operational position Figure 17 shows the chassis and the tool assembly in an operational position and rotated to a desired orientation for performing an edge modification operation at a corner of the object.

Figure 18 shows a tool head of the tool assembly located at a corner of the object Figure 19 shows a tool head of the tool assembly located at a corner of the object and with an edge sensor and tool bit in an offset position and adjacent a second edge of the object. Figure 20 shows a tool head of the tool assembly located at a corner of the object and with an edge sensor and tool bit in an aligned position with the edge sensor in contact with the second edge of the object.

Figure 21 shows another view of the tool head in the same position as in Figure 20. Figure 22 shows the tool head of the tool assembly located at another corner of the object.

Description of a preferred embodiment of the invention

In the broadest sense the apparatus as herein described may provide a multipurpose apparatus for modifying an edge of an object. The object may be any object such as a piece of furniture, a construction panel, or planar objects or any other objects that may require an edge modification. The edge modification generally entails applying an edge tape or an edge band to the object. Such edging may be wood veneer, plastic, melamine or high-pressure laminate or any other suitable materials that are applied to the edge of the object to provide the object with increased durability and wear resistance that would otherwise be non-existent if no edge tape or edge band were applied.

The term "modification" as used herein is meant to include any one or more of the following; cutting, trimming, sanding, smoothing, gluing, painting and deposition of edging, and other possible processes. For example, the apparatus may provide a roller to apply paint to an edge of the object. While particular emphasis is given to the capability of the apparatus in respect to applying edge tape or an edge band to the edge profile of an object, it should not be considered as being exclusively for this purpose.

Figures 1 and 2 show an embodiment of an edge modification apparatus in accordance with the present invention. Figures 1 and 2 show an edge modification apparatus 100 particularly, but not exclusively, suited for edge banding i.e. applying an edge tape or edge band to an object such as a panel or a piece of furniture. Other objects can also be edge modified by the edge modification apparatus and method as described herein.

Figure 1 shows an embodiment of the edge modification apparatus 100. Figures 2 and 3 show views of parts of the edge modification apparatus 100. Referring to Figure 1, the apparatus 100 comprises a base structure 102. The base structure 102 comprises one or more legs 104 that carry the base structure 102. The base structure 102 includes a bed 106. The bed 106 may be a flatbed structure and rests on the base structure 102. Alternatively, the bed 106 may be a pod and rail arrangement or potentially some kind of transfer loading table.

The bed 106 includes one or more supports 108 configured to support a panel in an operational position. As seen in Figure 2 the platform 106 includes a plurality of supports 108 configured to retain a work piece such as panel 1. In one exemplary form the supports are vacuum cups or suction cups that retain and hold the object 1 in an operational position. Alternatively, the supports 108 may include other removable retention features such as clips or clamps or the like. The supports 108 retain the panel 1 in an operational position such that the edge modification apparatus 100 can modify the edge 10 of the panel 1. For example, by applying an edge tape or edge band to the edge 10. The object 1 does not move relative to the bed 106 during an edge modification operation.

The apparatus 100 comprises one or more longitudinal rails 110 extending substantially longitudinally along the base structure 102. In the illustrated embodiment of Figure 1, the apparatus 100 comprises two parallel longitudinal rails 110 with one rail obscured from view. The apparatus 100 further comprises one or more transverse rails 112. In the illustrated embodiment the apparatus 100 comprises two transverse rails 112 extending transversely across the platform 106.

The edge modification apparatus comprises a chassis 120. The chassis 120 is made from a rigid material such as a metal for example steel, or stainless steel or any other suitable rigid, durable material. The chassis 120 supports a plurality of components. These components of the chassis 120 may be made of a suitable material such as for example steel or alternatively some of the components may be made of plastics material.

The chassis 120 is moveable relative to the panel 1 in an at least two directions. The chassis 120 is mounted to a carriage 122. The carriage 122 is moveably mounted on the longitudinal rails 110 such that the carriage can move or translate along the rails parallel to a longitudinal axis of the base structure 102. The chassis 120 is also connected to a frame 124. The frame 124 is moveably mounted to the transverse rails 112 such that the frame 124, and the connected chassis 120 can also move along the transverse rails along a transverse axis, transverse to the longitudinal axis of the base structure 102. The movement of the carriage 122 and the frame 124 move the chassis 120 in two dimensions. The chassis 120 can also rotate about its own vertical axis that is parallel to a vertical C axis. The frame 124 supports a spool 126 of edge tape or edge band. The spool 126 is rigidly connected to the frame 124 and may be rotatable about a shaft that is connected to and extends laterally across the frame 124. The spool 126 provides a supply of edge tape or edge band through a channel, across a glue head and onto an edge 10 of the panel 1 for adhesion on to the edge 10. The spool 126 also includes a replaceable magazine or reel that can be inserted into the spool 126. Preferably the edge tape or edge band is pulled from the spool during operation by a roller such as a tape feed roller (described later).

Alternatively, the spool 126 may be coupled to a spool motor that may be configured to rotate the spool 126 at a desired speed to provide an adequate feed rate of tape. The spool motor may be any suitable motor and may be controlled by any suitable drive such as a variable speed drive. Preferably the operation of the spool tape is controlled by the controller 220. The spool motor may be a PLC or variable speed drive controlled motor. The spool motor may also be located in any suitable location.

The edge modification apparatus 100 further comprises a force application arrangement coupled to the chassis 120 and configured to drive the chassis 120 such that a force can be applied to the edge via a roller 202 (Figure 3).

The force application arrangement comprises a first motor 130 (refer Figure 15) and a second motor 132 (refer Figure 15). The first motor 130 is connected to the carriage 122 and drives the carriage in a direction along the longitudinal rails 110. The second motor 132 is connected to frame 124 and drives the frame 124 in a direction along the transverse rails 112.

The first motor 130 and the second motor 132 are controlled by variable speed drives. The variable speed drives are configured to operate in multiple modes, wherein one mode is a positional control mode and the other mode is a torque control mode. The variable speed drives can control the first motor 130 and the second motor 132 to act as vector drives. In positional control mode, the first and second motors are configured to move the chassis 120 and hence the roller 202 relative to the object in at least two dimensions i.e. parallel to the longitudinal rails or the transverse rail. In positional control mode, the first motor 130 controls movement of the chassis 102 and contact roller 202 along the longitudinal rails 110 in the longitudinal direction and the second motor 132 controls the movement of the chassis 130 and roller 202 along the transverse rail 112 in the transverse direction. In positional control mode, the first and second motors together provide a drive mechanism to move the chassis relative to the fixed structure in the coordinate system.

The first and second motors 130, 132 may be any suitable motors and include other components that allow operation of the motors and movement of the carriage 122 and the frame 124 on respective rails 110 and 112 and to apply a force to the object edge during movement of the carriage and the frame on respective rails 110 and 112. For example, timing belts and/or rack and pinion mechanisms coupled between the first motor and longitudinal rails and the second motor and transverse rails can be used.

The variable speed drives are configured for use in accurate torque control of the first and second motors 130, 132 i.e. can function to apply a controlled torque to apply a controlled force to the contact roller 202 and hence allow the roller 202 to apply a controlled force to an edge of the object 1. In torque control mode, the first motor 130 provides a linear force component to the roller 202 (via the chassis 120 carried by the carriage 122 on the longitudinal rails 110) in the longitudinal direction, and the second motor 132 provides a linear force component to the roller 202 (via the chassis carried on the transverse rails 112) in the transverse direction. In torque control mode, the first and second motors together provide a force application arrangement configured to drive the chassis to provide a force to the edge of the object via the roller 202.

In the illustrated example of Figure 1 the longitudinal rails 110 represents movement in the X direction or parallel to an X axis. The transverse rail 112 represents movement in the Y direction or parallel to a Y axis. Therefore, in positional control mode, the first motor 130 controls the X position and the second motor 132 controls the Y position of at least the contact roller 202. And in the torque control mode, the first motor 130 controls the force applied by the roller in the X direction and the second motor 132 controls the force applied by the roller in the Y direction. In the illustrated embodiment the X axis is parallel to the longitudinal rails 110 and the Y axis is parallel to the transverse rail 112. The use of the Cartesian system will be described later. It is also contemplated that other coordinate systems can be used for determining position and/or force direction of the roller 202 as described later. Furthermore, alternative movement mechanisms to move the chassis relative to the fixed structure may be provided. For example, the apparatus may comprise a swinging length-adjustable (e.g. telescopic) arm with a first motor driving an angle of the arm and a second motor driving length adjustment of the arm.

As shown in Figure 3 the chassis 120 comprises a central shaft 160 i.e. a C axis shaft. A vertical 'C axis is shown in Figure 3. The chassis 120 is rotatable about the C axis/central shaft 160. The contact roller 202 is mounted directly to the C axis shaft. The edge modification apparatus 100 comprises a roller drive device and a chassis drive device. In the illustrated example the roller drive device is a C axis motor 162 (refer Figure 15) that rotates the shaft 160 to drive rotation of the contact roller 202 to drive the roller along the edge of the object. The chassis drive device is a chassis drive motor 164 (refer Figure 15).

The chassis drive motor 164 may be mounted on the frame 124. The chassis drive motor 164 is configured to drive the chassis to rotate the chassis about the C axis shaft 160. The chassis drive motor 164 and C axis motor 162 can be any suitable motor and can be controlled by any suitable controller such as a variable speed drive or a PLC or any other suitable motor controller. The central shaft 160 also comprises a sprocket 166 (refer Figure 15) that couples to a drive assembly such as a belt or chain drive (not shown for clarity). The drive assembly is coupled to and driven by the chassis drive motor 164.

The sprocket 166 transmits the motion or forces from the chassis drive motor 164 to the chassis 120 and rotates or moves the chassis 120 relative to the central shaft 160 i.e. around the C axis.

The edge modification apparatus 100 comprises a sheath 168 that encases the central shaft 160. The sheath 168 may be formed from a durable, rigid material such as a steel or stainless steel or any other suitable material. The chassis 120 is rigidly coupled to the sheath 168 by connecting rods or connecting arms or other suitable connectors or fasteners. The sheath 168 is rotatable about the shaft 160 and the shaft 160 passes through the sheath 168. The sheath 168 preferably rotates due to a driving force from the sprocket 166 and thereby causes the chassis 120 to rotate or move relative to the central shaft 160. The sheath 168 preferably runs inside large bearings which are mounted on the chassis 120, in which the sheath can rotate. The central shaft 160 can rotate independently and is driven by its own separate motor 162.

Referring to Figure 3 there is shown a detailed view of the chassis 120 and the various components supported by the chassis 120. The chassis 120 carries a channel or guide 140 and a glue head 150. The channel or guide 140 guides an edge tape to be applied to the edge of the object past the glue head 150 and onto the edge 10 of the object. The channel 140 may comprise a plurality of runners or wheels 142 that prevent the tape from tangling with within the channel 140 and also reduce the tape from catching or getting stuck within the channel 140.

The glue head 150 is an assembly of components that houses glue and provides the glue to the edge tape or edge band prior to the edge tape or edge band being laid onto the edge 10 of the object 1. The glue head 150 and its components are mounted to the chassis 120 using any suitable mounting fasteners or other coupling arrangements. The glue head 150 may be moveable relative to the object 1 as the chassis 120 moves.

The glue head 150 comprises glue cartridge 152 that acts as a glue reservoir and holds a volume of glue. The glue cartridge 152 may be a replaceable cartridge such that the cartridge is replaced when the cartridge is emptied. Alternatively the glue cartridge may be a refillable cartridge. The cartridge 152 may be a pressurised cartridge or may include an actuator to push glue out at a desired rate and volume. The glue head 150 includes a plurality of glue nozzles that extrude glue onto the edge tape or edge band as the edge tape or edge band is dragged in contact with or adjacent the glue nozzles. For clarity the nozzles are not shown in the current figures. Alternatively, the glue head 150 may comprise any other suitable applicator. International patent application publication W02019/035017, the contents of which is incorporated herein by reference, discloses further details of a suitable glue applicator arrangement. Alternatively, the edge tape may be provided with an adhesive applied to a back of the tape.

As seen in Figure 3, the glue head 150 includes a tape feed roller 154. The tape feed roller is preferably a driven roller. In one example the tape feed roller 154 may be driven by the C axis motor 162 that drives the contact roller 202. In this example the tape feed roller 154 may be removably connected to the contact roller 202 by a drive mechanism such as a belt or chain drive. The C axis motor 162 rotation of the contact roller 202 also rotates the tape feed roller 154 in order to push tape on to the edge as the contact roller 202 is driven. The tape feed roller 154 being commonly driven by the pressure roller 202 is advantageous because it synchronizes tape being feed as the pressure roller 202 starts being driven. The tape feed roller 154 is configured to feed the edge tape or edge band past the glue nozzles and onto the edge. As soon as the edge tape or edge band contacts the edge and is under the pressure roller, the tape feed roller 154 is disengaged. The glue head 150 may include appropriate sensors, for example a photoeye or photoelectric sensor, to detect the contact between tape and the edge. The glue head 150 also includes an appropriate mechanism to disengage the tape feed roller 154 from the pressure roller 202. Alternatively, the tape feed roller 154 may be driven by its own associated motor that is controlled by an associated PLC or variable speed drive. International patent application publication W02019/035017, the contents of which is incorporated herein by reference, discloses further details of a suitable glue applicator.

The edge modification apparatus 100 further comprises a plurality of cable conduits to house a variety of cables such as power cables to the various motors in the edge modification apparatus 100. The cable conduits house and protect cables and assist in cable management such that the cables remain clear of the moving parts of the apparatus 100.

Referring at least to Figures 1 to 3, the edge modification apparatus 100 further comprise a roller assembly 200 and a cutter assembly 300. The roller assembly 200 and the cutter assembly 300 comprise a plurality of components. The roller assembly 200 and the cutter assembly 300 are mounted on the chassis 120. International patent application publication W02019/035017, the contents of which is incorporated herein by reference, discloses further details of a suitable cutter assembly 300.

The roller assembly 200 comprises the contact roller 202. In the illustrated embodiment of Figures 1 to 3 the roller assembly comprises the contact roller 202 and a trailing roller 204. In the illustrated embodiment shown in Figures 1-4 the contact roller 202 is a pressure roller 202. The pressure roller 202 is configured to apply a pressure to the edge 10 of the object 1 in order to adhere the edge tape or edge band to the edge 10 of the object 1. As described above, the pressure roller 202 is preferably directly coupled to the central shaft 160 (i.e. the C axis shaft). The pressure roller 202 is preferably a circular roller and is configured to apply a force i.e. a pressure against the edge 10 of the object 1 to adhere the tape 11 to the edge. The pressure roller 202 is configured to apply a vectored force. The vectored force is defined by a direction and magnitude. More specifically the pressure roller 202 is configured to apply a force of a predetermined magnitude or a desired magnitude along a desired force direction.

The pressure roller 202 applies the force to the edge of the object. The force applied by the pressure roller relates to the force that is exerted by the first and second motors 130, 132. As described above, the variable speed drives function in a torque control mode to apply a controlled torque hence causing the first and second motors 130, 132 to apply a controlled force to the pressure roller 202 in the X and Y directions. The pressure roller 202 in turn is arranged to apply the controlled force to the edge of the object.

The trailing roller 204 trails the pressure roller 202. Preferably the trailing roller 204 is rigidly connected to the chassis 120 by a suitable connector such as a connecting arm. Since the chassis 120 can pivot about the C axis, the trailing roller 204 also is capable of pivoting about the C axis due to the chassis 120 pi voting/ rotating on the C axis.

The trailing roller 204 is preferably positioned between the pressure roller 202 and the cutter assembly 300. The trailing roller 204 functions as a spacer to space the cutter assembly 300 away from the pressure roller 202. The trailing roller 204 preferably prevents the cutter assembly 300 from colliding with or interfering with the pressure roller 200, by spacing the cutter assembly 300 away from the pressure roller 202.

The trailing roller 204 is rotatable on a shaft and can rotate in use as it moves along the edge 10. The trailing roller 204 is configured to pull the cutter assembly 300 behind it, along the edge of the object 1. The trailing roller 204 preferably remains in contact with, moves along the edge and pulls the cutter assembly 300 along the edge behind the trailing roller 204.

The trailing roller 204 is preferably co-driven with the pressure roller 202, by the C axis motor 162. The C axis motor 162 drives both the pressure roller 202 and the trailing roller 204, preferably at the same speed. The trailing roller 204 is coupled to the pressure roller by linkage 206. The linkage 206 may be a chain drive or belt drive that couples the pressure roller 202 and trailing roller 204. The linkage 206 transmits drive forces to the trailing roller 204 to rotate the trailing roller as rotation of the pressure roller 202 is driven by the C axis motor 162. The linkage 206 may also comprise an arm linking the pressure roller 202 and the trailing roller 204. The length of the linkage 206 is preferably short enough to reduce drag of the trailing roller 204 and hence the cutter assembly 300. In an alternative embodiment the linkage 206 may comprise a pivoting arm that is configured to pivotably couple the trailing roller 204 to the pressure roller 202.

The trailing roller 204 is preferably rigidly connected to the chassis 120 such that the trailing roller 204 is moved relative to the object 1 as the chassis 120 moves. As discussed earlier the chassis 120 can rotate or move about the central shaft 160 i.e. about the C axis. The rotation of the chassis 120 on the C axis urges the trailing roller 204 in contact with the edge 10. The trailing roller 204 applies a contact force to the edge of the object 1.

The chassis drive motor 164 is configured to apply a torque to the chassis 120 and hence apply a torque to the trailing roller 204 to urge the trailing roller 204 against the edge 10. The trailing roller 204 applies a contact force to the edge of the object. The contact force applied to the edge is based on the torque applied by the chassis drive motor 164. The torque on the trailing roller 204 is preferably a predetermined torque to maintain contact between the trailing roller 204 and the edge. The contact force applied by the trailing roller 204 can be adjusted manually or automatically, preferably automatically. For example the contact force applied by the trailing roller 204 may be reduced on corners to reduce drag from the trailing roller 204 on the pressure roller 202. This is achieved by automatically controlling the torque applied by the chassis drive device i.e. the chassis drive motor 164. By rotating the chassis on the C axis to maintain contact between both the contact roller 202 and the edge of the object and the trailing roller 204 and the edge of the object, rotation of the chassis on the C axis places the chassis in a known orientation relative to the edge of the object. In some embodiments the apparatus may be without a trailing roller 204. The apparatus may comprise one or more sensors to detect an edge of the object to orientate the chassis relative to the edge of the object.

The speed of rotation (i.e. the speed) of the pressure roller 202 and the trailing roller 204 may be set to a desired or predetermined speed and can be controlled depending on the shape of the edge 10. The roller drive device, in this example, the C axis motor 162 is controlled to drive the pressure roller 202 at a predetermined speed to allow enough contact time between the pressure roller and a section of edge tape or edge band to adhere the edge tape or edge band onto the edge 10 of the panel 1. Rotation of the pressure roller drives the roller along the edge of the object and determines the speed at which the roller (and trailing roller) moves along the edge. The roller 202 traces the edge of the object as it is driven along the edge by the C-axis motor. Thus, the roller is positioned in the coordinate system by the contour of the edge of the object. With the first and second motors in torque control mode the apparatus does not otherwise control the position of the roller in the coordinate system.

The speed of the pressure roller 202 can be varied based on the geometry of the edge. For example the speed of the pressure roller 202 and the trailing roller 204 may be reduced on non-linear sections of the edge as compared to linear sections of the edge. In an example the speed of at least the pressure roller 202 is reduced at tight corners or sharp corners to reduce chance of the rollers 202, 204 from slipping off the edge 10. Reducing speed around sharp corners also helps to enhance the glue bond to overcome any memory or resilient forces in the band, and ensure the band is correctly adhered to the edge of the panel. In a further example the speed of the pressure roller 202 may be slowed when approaching an inside corner 12 or an outside corner 14. The pressure roller 202 is driven to rotate at a constant speed to thus move along straight sections 16 at a constant speed. Alternatively, the speed of the pressure roller 202 may be variable on at least the linear or straight sections of edge. The speed of the pressure roller 202 is a predetermined speed. The predetermined speed may be dependent on a number of variables such as the material of the panel, the type of glue, the type/material of the edge tape, the dimensions of the panel etc.

The edge modification apparatus 100 comprises a controller 220. In one exemplary embodiment the edge modification apparatus 100 comprises a controller that is an electronic controller comprising at least a non transitory memory unit, a processor unit and a plurality of communication links or channels to communicate with other components of the edge modification apparatus such as the various motors or the variable speed drives. The communication links or channels may be wired or wireless connections. The processor may be any suitable electronic processor and the memory unit may be RAM, ROM, flash memory or any other suitable memory unit. The motors of the edge modification apparatus and other actuators etc. may be controlled by the central controller 220 or may be controller by their own associated controllers. The controllers associated with each of the motors and actuators can also be controlled by the central controller 220 via its communications links or channels. In one example the central controller 220 may be a PLC or other suitable controller. The controller may also be in electronic communication either wirelessly or by wired connection to a user interface 222 that can display information to a user and allow a user to input information.

The memory unit of the controller 220 is configured to store information such as predetermined pressure roller drive speeds or may also receive and store information from one or more sensors positioned on the edge modification apparatus 100. The controller 220 may be configured to control the C axis motor 162, the chassis drive motor 164, the first motor and second motors 130, 132 or the variable speed drives associated with the first and second motors 130, 132 through wired or wireless connections. Preferably the controller 220 is in electronic communication with the drives e.g. variable speed drives of the motors 130, 132, 162 and 164 to control operation of the motors. Alternatively, the controller 220 may be configured to directly control motors 130, 132, 162 and 164.

The pressure roller 202 is urged against the edge 10 to provide a pressure on the edge to adhere the edge tape or edge band to the edge 10. The contact roller 202, specifically the pressure roller may be used in other edge modification processes. In order to get good adhesion, it is desirable to apply a force of appropriate magnitude at an angle normal to the edge of the object i.e. perpendicular to a tangent to the edge at the point of contact between the pressure roller 202 and the edge of the object 1. The force from the pressure roller 202 helps to create adhesion between the edge tape and the edge. Applying a force or an appropriate magnitude at a normal angle helps to urge the edge tape against the edge of the object.

As discussed earlier the pressure roller 202 applies a force defined by a force vector. The force vector is defined by a force direction and a force magnitude applied to the edge 10 by the pressure roller 202. The force magnitude and direction is provided by the X and Y motors when in Torque control mode. The force direction is preferably substantially normal to the edge 10 of the object 1. A substantially normal force direction is preferable because it provides optimal force to adhere the edge band or edge tape to the edge of the object.

The force application arrangement i.e. the first and second motors 130, 132 are configured and controlled to force the pressure roller 202 against edge 10 of the object 1. The first and second motors 130, 132 are controlled such that the pressure roller 202 applies an initial force in a force direction approximately normal to the edge.

The position of the pressure roller 202 and/or application of a force by the roller may be determined on a coordinate system. In the illustrated example a Cartesian system is used. The apparatus 100 may define a global Cartesian coordinate system such that each position of the object 1/roller 202 is defined on a global coordinate system. Each position of the pressure roller 202 and/or direction of force applied by the roller 202 may be defined by or relative to an X and Y coordinate in the global Cartesian plane.

Alternatively the position/force direction of the pressure roller 202 may be determined as a radius and an angle (r, Q) on a polar coordinate system.

The edge modification apparatus 100 comprises a sensing arrangement to detect a position of a contact roller 202 and/or a position of the chassis 120 and/or component on the chassis in a coordinate system. The sensing arrangement comprises one or more position sensors configured to measure a position of a contact roller 202 and/or a position of the chassis 120 and/or component on the chassis in the coordinate system. For example, the first motor 130 and second motor 132 may include one or more encoders to control position of the roller and/or application of force in a global coordinate system.

The encoders provide X and Y positions of the pressure roller 202 with a sub millimetre resolution. The encoders may have a resolution of lOths or lOOths of a millimetre. In one example the edge modification apparatus 100 comprises 5000 pulse encoders that are in communication with the controller 220. The position sensors (e.g. encoders) are configured to sense (i.e. track) the position of the roller 202 as the roller moves along the edge 11. In exemplary embodiment the encoders are configured to sense the position of the centre of the pressure roller 202/C axis. The controller 220 is configured to process the received signals from the encoders and measure a position of the pressure roller 202 in the global coordinate system 1000 as the roller moves along the edge of the object. As the roller moves along the edge of the object each recorded position of the pressure roller 202 is defined by a corresponding X and Y coordinate (or polar coordinate). The position of the roller is tracked continuously, for example a roller position is recorded by the controller every 1mm, or 2mm, or 3mm of travel along the edge of the object. As an alternative or additionally the apparatus may comprise other position sensors such as optical sensors or hall-effect transducers or piezoelectric sensors or other suitable sensors that are configured to measure the position of the pressure roller 202 in the global coordinate system 1000. The position sensors are mounted at suitable locations to measure the position of the pressure roller 202 on the edge of object 1 to provide a position of the roller within the global coordinate system 100.

The controller 220 may be configured to store or record the X and Y coordinates when the pressure roller 202 first makes contact with the edge 10 of the panel 1 (i.e. object 1). Alternatively, the edge modification apparatus 100 may comprise a suitable sensor such as for example a photo electric sensor or photo-eye or a sensing shoe or a sensing bar that is configured to detect the pressure roller 202 contacting the edge 10 of the object 1. Alternatively, a limit switch or an infrared sensor or other sensor can be used to detect contact between the pressure roller 202 and the edge 10 of the panel 1.

The initial position of the pressure roller 202 at the contact point with the edge 10 is preferably stored in the memory unit of the controller. Once the pressure roller 202 is in contact with the edge 10, the controller 220 is configured to switch the variable speed drives into the torque control mode. In torque mode the variable speed drives control the force application arrangement, specifically the first and second motors 130, 132 (i.e. the X and Y motors) to provide a predetermined force onto the edge of the panel 10 via the pressure roller 202. The predetermined force may be a constant force. Alternatively, the controller 220 may be configured to control the motors 130, 132 to provide variable force on the edge at different edge profiles.

Each motor comprises a gearbox that is geared to provide a specific force at 100% torque to the drive belts. The controller 220 controls the variable speed drives to apply a predetermined force i.e. a predetermined pressure along a force direction of a force vector. In one example at 100% the 1000N of force can be delivered. The controller 220 is configured to control the variable speed drives to deliver up to 1000N on the edge 10 of the panel, through the pressure roller 202. In one example a constant force of 600N is applied by the pressure roller 202 to the edge 10 of the panel. Other force levels can be applied and the controller 220 is configured to control the variable speed drives to vary the force delivered by the pressure roller 202. The level of force applied may be dependent on the type of edge tape used, the size of the panel, the size, the materials of the edge tape, the type of adhesive etc.

The controller 220 may be configured to store a plurality of different force settings in the controller memory that can be accessed and used by a user. In a further example controller 220 may also be configured to vary the force applied by the pressure roller 202 based on the location of the pressure roller 202 or based on a shaped or geometry of the edge 10.

As described above, the force applied by the pressure roller 202 is defined by a force vector. The force direction of the force vector is preferably substantially normal to the edge 10 of the panel 1. The motors 130, 132 act on the chassis 120 and the pressure roller 202 to provide a force along a desired force direction and at a desired magnitude. As the force direction is substantially normal to the edge 10 of the panel 1, the desired force direction changes along the profile of the edge 10 as the pressure roller 202 is driven along the edge 10 by the C-axis motor, in order to act substantially normal to the edge. It is useful to deliver a force (i.e. pressure) from the pressure roller 202 that is substantially normal to the edge 10 of the panel 1 to ensure that the edge tape is correctly placed and adhered to the edge 10. The magnitude of the force is preferably constant as the pressure roller 202 moves along the edge to ensure enough pressure is applied to the edge tape or edge band to cause adhesion of the edge tape or edge band to the edge 10. If the pressure roller 202 acts substantially tangentially to the load, the edge tape or edge band may be misaligned or the pressure roller 202 may become disengaged from the edge 10 or cause the edge band/edge tape to slip or bunch.

The controller 220 is configured to determine a desired force direction at small intervals, and control the X and Y motors to apply the force vector in accordance with a desired force direction (i.e. direction of the force vector). The magnitude of the force may be constant at all locations such as for example 600N. However, the controller 220 is configured to control the force application arrangement (i.e. the first motor 130 and the second motor 132) to provide a constant force along the desired force direction as the roller traverses along the edge of the object.

The controller 220 may be configured to control the force application arrangement to vary the magnitude of the force applied to the edge 10 by the pressure roller, based on or more parameters such as the type of edge tape or edge band, a geometry of the edge, the type of adhesive being used or any other suitable parameter.

A method for determining the direction of force substantially normal to the edge of the object as the roller 202 travels along the edge is described in international patent publication W02019/035017, the contents of which is incorporated herein by reference. An apparatus using the disclosed method uses a tracked position of the pressure roller to determine the force direction based on adjacent positions of the roller as the position if the roller is tracked along the edge of the object.

Operation of the apparatus to provide a tape to an edge of the object is now described with reference to Figures 1 and 4 to 7.

A continuous length of edge tape is applied to the edge of the object between non-radiused corners of the object. The tape is cut at non-radiused corners as the tape cannot bend about a sharp/non-radiused corner. For example, for a rectangular panel, an edge tape will be applied to one edge extending between corners of the rectangle. Once the edge tape has been applied to an edge of the object, the edge tape will be cut at the corners before applying an edge tape to adjacent edges of the object.

In Figure 1 the object 1 is substantially rectangular with one radiused corner lOr between two adjacent edges of the rectangular object. The radiused corner allows for a tape to be applied continuously between the edges of the rectangular object extending on either side of the radiused corner. The illustrated object therefore has three edges 10-1, 10-2, 10-3 extending between non-radiused corners lOcl, 10c2, 10c3, each of the three edges 10-1, 10-2, 10-3 to receive a single continuous length of tape. A single edge of the object is considered to be an edge to which a continuous length of tape may be applied. An edge of the object may comprise a radiused corner or other contour with a minimum radius of curvature larger than a minimum bend radius of an edge tape to be applied to the edge.

In the illustrated embodiment, and as shown in Figure 1, the apparatus comprises a start or lead block 171 and an end or trailing block 172. Each block is secured to the bed 106 against movement. For example, the blocks 171, 172 may comprise suction cups to retain and hold the blocks on the bed 106. The lead block 171 is positioned with an edge or side of the block aligned with a lead portion of an edge 10-2 of the object, and the trailing block 172 is positioned with an edge or side of the block aligned with an end portion of the same edge 10-2 of the object. An operator may secure the object to the bed 106 and then position and secure each of the lead and trailing blocks in position relative to the object as described and illustrated by example in Figure 1. Where an edge includes a non-linear contour, such as the edge of the object 1 in Figure 1 comprising a radiused corner lOr, the lead block 171 will be at an angle to the end block 172. For a linear (straight) edge, the lead and end blocks will be aligned.

Prior to or at the beginning of an edge modification operation, the roller 202 is positioned away from the edge of the object, for example placed manually by an operator or automatically to a predetermined coordinate in the coordinate system as shown in Figure 4. In the illustrated embodiment the chassis is mounted to the frame 124 to move vertically between a raised parked position and a lowered operational position. The roller assembly may be moved vertically by an actuator such as a motor, rack and pinion arrangement or cylinder (pneumatic or hydraulic), for example actuator (cylinder) 114 shown in Figure 15. The chassis is moved to the lowered position to carry out an edge modification process. Figure 4 shows the chassis in the lowered position and spaced from the lead block. With the X and/or Y motors 130, 132 initially in position control mode, the controller controls the X and/or Y motors to move the chassis 120 relative to the bed and therefore object to bring the roller 202 into contact with the lead block 171 aligned with the edge 10-2 of the object 1. The roller 202 may be moved in a direction perpendicular to the edge 10-2 of the object or lead block (indicated by the arrow in Figure 4) until contact is made with the lead block 171. To move the roller 202 to make initial contact with the lead block 171, only the second motor 132 may be driven to move the roller in the Y direction along rails 112, with no movement provided in the X direction by the first motor 130. Depending on which edge apparatus is to apply the edge band, only the first motor 130 may be driven to move the roller in the X direction along rails 110, with no movement provided in the Y direction by the second motor 132. Figure 5 shows the roller 202 in contact with the lead block 171. Alternatively, an operator may initially place the roller in contact with the edge of the lead block 171.

Once in contact with the lead block 171, the first and second (the X and Y) motors are then switched to torque control mode to apply a vectored force normal to the edge of the object.

For example, at the initial contact, only the Y motor 132 may provide a predetermined force in the Y direction against the edge of the lead block 171. The controller then controls the C-axis motor 162 to drive rotation of the roller 202 to move the roller along the lead block (indicated by the arrow in Figure 5). Rotation of the roller 202 causes the roller to move along and follow the edge of the lead block towards the corner lOcl of the object. As the roller traces along the edge of the lead block, the apparatus continuously determines the vectored force to be applied to the edge, for example as described in W02019/035017. The apparatus feeds the tape (101 in Figures 6 and 7) onto the lead block 171 so that the roller presses the tape against the edge of lead block as the roller 202 moves along the lead block 171 with the tape 101 between the roller 202 and the lead block 171. The roller 202 drives along the lead block 171 and then onto the edge 10-2 of the object 1 as shown in Figure 6 to then continue along the edge 10-2 of the object to apply the edge tape 101 to the edge of the object. Thus, the edge tape overhangs the edge 10-2 of the object onto the lead block 171 and must be subsequently cut flush to the corner of the object (as described below). As the roller 202 moves along the edge 10-2, the controller continuously controls the X and Y motors in torque control to continue to provide a vectored force to the edge of the object. The roller reaches the end region of the edge 10-2 and continues to drive off the end of the edge 10-2 and onto the end block 172, as shown in Figure 7. A cutter (not shown) cuts the tape so that the tape 101 overhangs the edge 10-2 of the object onto the end block 172 and must be subsequently cut flush to the corner lOcl of the object (described below). Figure 8 shows the edge tape 101 applied to the edge 10-2 of the object with end portions of the tape overhanging the edge onto the lead and end blocks. The overhanging excess portions of tape are cut in a subsequent trimming operation, described below. Note that in Figure 8 a full width of the edge tape is shown on the edge of the object. However, typically the cutter assembly 300 cuts an upper portion and a lower portion from the tape as the pressure roller traverses the edge of the object so that the tape does not extend beyond an upper surface of the object and a lower surface of the object.

To ensure accurate cutting of the edge tape at the corners 10c of an object 1, or to provide other edge modification process at a corner of the object, it is desirable to accurately determine the position of non-radiused corners 10c (herein a corner) of the object in the global coordinate system. A preferred method for determining the location of a corner of an object is now described.

Corner position determination

The object 1 has a first edge 10-1 and an adjacent second edge 10-2. The first and second edges each extend from a corner lOcl of the object. In Figure 1 the first and second edges are identified as 10-1 and 10-2, and the corner lOcl. The apparatus moves the roller towards the corner lOcl. For example, as described above and as shown in Figures 5 and 6, at the beginning of an edge modification process the roller 202 runs along the lead block 171 towards the corner lOcl of the object in the direction of the arrow in Figure 5, and as shown in Figure 7 the roller 202 runs along the edge 10-1 of the object towards the corner 10c2. Preferably the apparatus moves the roller towards the corner lOcl, 10c2 in a direction parallel to the lead and end portions of the first edge and with the roller in contact with or aligned with the lead and end portions of the first edge 10-2. Most preferably the roller is driven along the first edge 10-1 or a lead block by rotation of the roller by the C-axis motor against the edge/lead block as described earlier.

The apparatus comprises a sensor to sense an edge of the object. The sensor is preferably a non-contact sensor, such as an optical sensor, photo-eye or camera type sensor (e.g. CMOS sensor). The illustrated embodiment comprises a non-contact optical sensor with a sensor beam indicated by a cylinder in the Figures, for example sensor 210 with beam 211 in Figures 6 and 7.

The sensor 210 is position in a fixed relation to the centre of the roller 202. There is a known offset between the centre of the roller 202 (and therefore the C-axis) and the sensor 210. As the roller is driven towards the corner lOcl, the sensor is positioned to detect the second edge 10-2 of the object. Once the second edge has been detected by the sensor, the corner position can be determined from the known geometry of the roller (i.e. the roller diameter). The known offset between the roller and the edge sensor may also be used to determine the corner position, as described below.

Figure 9 shows a schematic representation of the lead block 171 and the object 1 with the roller 202 moved in alignment with the first edge 10-1 along the lead block 171. In one embodiment, the sensor is offset from the roller so that a line between the edge sensor 210 (that detects the edge at point P in Figure 9) and the roller centre C (and the C axis shaft centreline as shown in Figure 3) is perpendicular to the lead portion of the first edge 10-1. For example, as described above, the chassis motor rotates the chassis 120 relative to the object 1 about the C axis to orientate the chassis to the edge of the object. A line may be drawn between the sensor 210 and the C axis. The chassis is orientated relative to the edge of the object to achieve a known angle between the line and the edge of the object, for example perpendicular to the edge of the object. For an object with a 90-degree corner lOcl, and with the line between the sensor 210 and the C axis perpendicular to the edge 10-1, when the sensor 210 detects the second edge 10-2 the roller is positioned at the corner with the centre of the roller 202 aligned with the second edge 10-2. As described above, the position of the roller is tracked by the controller. Where the centre of the roller is known in the coordinate system, the corner position in the coordinate system may be determined by adding or subtracting the roller radius to or from the roller centre position in a direction along the line between the roller centre and the sensor position P.

In the illustrated embodiment the lead block and lead portion of the first edge provide a linear or straight path for the roller. Rotation of the chassis on the C axis by the chassis drive motor 164 places the trailing roller 204 in contact with the lead block to position the chassis in a known orientation relative to the edge of the lead block and therefore the lead portion of the edge 10-1 of the object. The known orientation of the chassis places the sensor 210 in a known position relative to the C axis and therefore centre of the roller 202 relative to the first edge 10- 1 of the object. The corner position could however be determined based on known geometry of a non-linear edge portion.

The angle between the line between the sensor 210 and the C axis and the edge of the object may be an angle other than perpendicular to the edge. With the chassis 120 in a known orientation to the edge of the object and lead block, the position of the corner lOcl may be calculated from the known relative positions of the roller 202 and sensor 210 fixed to the chassis.

In some embodiments the apparatus may determine the corner position for a corner with an angle of other than 90 degrees. The angle of the corner of the object may be less than or greater than 90 degrees. Figure 10 provides a schematic representation of the lead block 171 and the object 1 with the roller 202 moved in alignment with the first edge 10-1 along the lead block 171 towards the corner lOcl of the object with a corner angle greater than 90 degrees. The lead block 171 has a corresponding corner angle so that the sum of the corner angle of the object 1 and the corner angle of the lead block is 180degrees so that the edge of the lead block is aligned with the edge of the object. In this example, the roller 202 is adjacent the corner lOcl when the sensor 210 detects the second edge 10-2, prior to the roller 202 reaching the corner lOcl of the object. For a corner angle less than 90 degrees, the roller 202 is adjacent the corner lOcl when the sensor 210 detects the second edge 10-2 with the roller having travelled slightly beyond the corner of the object onto the first edge 10-1 of the object.

With reference to Figure 10, the position of the corner lOcl may be determined from the position of the roller when the second edge is detected by the edge sensor, the known offset between the centre of the roller and the sensor, and the angle of the corner of the object. For example, with the first edge parallel to the X direction in the coordinate system, where:

Y = the Y coordinate for the centre of the roller

X = the X coordinate for the centre of the roller

O = offset distance between the roller centre and the edge sensor r = radius of the roller

A = angle of the corner of the object

Yc = the Y coordinate for the corner

Xc = the X coordinate for the corner then:

Yc = Y + r

Xc = X - (O - r)/tan(180 - A)

The angle of the corner may be entered by an operator (for example via interface 222), or the corner may be detected, for example by a camera or cameras located above or below the bed of the apparatus or a second edge sensor between the roller and the edge sensor 210. If the edge sensor 210 and the second edge sensor detect the second edge at the same time then the corner is 90 degrees. If the corner is other than 90 degrees the corner angle can be calculated by trigonometry using the geometry of the sensors and roller (e.g. known offsets between the roller and the edge sensors). The above example is for a corner angle greater than 90 degrees. For a corner angle less than 90 degrees at the lead portion of the first edge, the coordinates for the corner of the object may be calculated as:

Yc = Y + r

Xc = X + (O - r)/tan(A)

As described above, the controller tracks the roller position as the roller moves in the coordinate system. In some embodiments, the controller determines the corner position based on a trajectory of the roller as the roller moves in a direction along the lead block or trailing block or edge of the object.

For example, the object may be mounted to the bed 106 with the first edge at an angle to the X and Y directions in the coordinate system. The controller may calculate the trajectory of the roller in the coordinate system based on a plurality of roller positions as the roller moves in a direction aligned with the first edge and determine an angle of the first edge in the coordinate system. The controller can then determine the corner position as described above and additionally based on the angle of the first edge in the coordinate system.

In some embodiments the angle of the first or second edge in the coordinate plane may be entered by an operator (for example via interface 222).

In some embodiments, the controller determines the angle of the first edge in the coordinate system based on the angular orientation of the chassis. As described above, in some embodiments the chassis is oriented relative to the edge to achieve a known orientation relative to the edge of the object. In some embodiments the apparatus comprises a sensor to sense an angular orientation of the chassis. For example, the chassis drive motor may include one or more encoder to provide an angular orientation or position of the chassis. For example, with the object arranged with its first edge parallel to the X axis, the chassis orientation sensor may be calibrated to provide an angle of 0 degrees with the chassis oriented to position a line drawn between the sensor 210 and the C axis perpendicular to the edge of the object. The controller is configured to determine that for a chassis angle of 0 degrees the first edge is parallel to the X axis (at 0 degrees to the X axis). For a chassis angle of for example 30 degrees, the controller can determine the angle of the first edge in the coordinate system is 30 degrees to the X axis.

In a further example, the controller may calculate the trajectory of the roller in the coordinate system based on a plurality of roller positions as the roller moves in a direction aligned with the first edge. The controller may determine a line extending on the first edge of the object in the coordinate system based on the trajectory. The controller may calculate the line of the first edge from the known radius of the roller and the trajectory of the centre of the roller. The controller may calculate a line of the second edge from the angle of the corner of the object, the position of the roller when the edge sensor detects the edge, and the offset between the roller position and the edge sensor. The line of the second edge runs through the point on the second edge detected by the edge sensor. The line of the second edge is at an angle to the first edge defined by the corner angle of the object. The controller can then calculate the corner position as the intersection point between the line of the first edge and the line of the second edge. Again, where the object edge is at an angle in the coordinate system, the controller may also use an angle between the trajectory of the roller and the X or Y axis of the coordinate system to determine the corner position. Alternatively or additionally the controller may use the angular orientation of the chassis as described above to determine the line of the first edge and the corner angle to determine the angle of the second edge and calculate the corner position as the intersection point between the line of the first edge and the line of the second edge.

In some embodiments the controller may determine a position in the coordinate system on the second edge 10-2 that is offset from the corner of the object. The controller may then use that point on the second edge (the offset corner position) to locate the corner of the object or locate a tool at the corner of the object (described below). The controller may locate the corner of the object without calculating the actual position of the corner of the object in the coordinate system. For example, in some embodiments the controller may determine the X and Y coordinates of a point on the second edge detected by the edge sensor 210. The point (P in Figures 9 and 10) on the second edge 10-2 detected by the edge sensor is at a known offset from the corner of the object/roller and can therefore be used to position the chassis and/or other tool of the apparatus at the actual corner of the object.

In some embodiments, the controller may determine the point P on the second edge 10-2 from the position of the roller 202 when the second edge 10-2 is detected by the edge sensor 210 and the known offset between the centre of the roller and the sensor. For example, with the first edge 10-1 parallel to the X direction in the coordinate system, where:

Yp = the Y coordinate for the edge sensor detection point on the second edge Xp = the X coordinate for the edge sensor detection point on the second edge then:

Yp = Y + O Xp = X

The apparatus may position a tool of the apparatus (described below) at the corner of the object by positioning the tool relative to the point on the second edge 10-2 offset from the corner.

It is to be understood that the position of the centre of the roller may be detected/measured by tracking/recording the position of another component of the apparatus 100 carried by the chassis 120 and at a fixed relation to the roller. For example, the controller 220 may record the X and Y coordinates of the position of the sensor 210 in the coordinate system as the roller travels along the edge of the object. The position of the roller (i.e. the C axis) may be calculated from the position of the sensor 210 and a known offset between the sensor and the roller. The roller position may not necessarily be calculated, with the position of another component in fixed relation to the roller utilised as the roller position in a corner location determination method.

To determine the position of the corner 10c2 at the end portion of the first edge, the roller tracks along the first edge until the edge sensor detects a third edge 10-3. For ease of reference, the third edge may be considered a second 'second edge'. The controller may determine if an object corner is at the leading portion or trailing portion of the first edge by the edge sensor 210 detecting a rising edge of the object (at the leading portion of the first edge) or a falling edge of the object (at the trailing portion of the first edge). In this case, the second edge 10-2 is a rising second edge, and the third edge 10-3 may be referred to as a falling second edge.

Once the second edge 10-3 is detected, the position of the second corner may be calculated using the known geometry of the roller, edge sensor, corner angle and angle of first edge in the coordinate plane as described above. In the illustrated embodiment the end portion of the first edge and the end block provide a linear or straight path for the roller to move along. The corner position could however be determined based on known geometry of a non-linear edge portion.

In the illustrated embodiment each of the lead block and the end block comprises a notch or slot (herein a notch) 173. The block 171, 172 has a first edge to be aligned with the first edge 10-1 of the object and a second edge to abut the second edge 10-2 of the object. A corner angle of the block between the first and second edge of the block is equal to 180 degrees minus the corner angle of the object. The notch 173 is provided at the second edge of the block to present a gap between the second edge of the object and the second edge of the block. The gap presents a portion of the second edge of the object to be detected by the edge sensor. Alternatively, the block 171, 172 may present a feature to be detected by the edge sensor to thereby (indirectly) detect the second edge by a known offset between the feature and the second edge with the block 171, 172 abutted against the second edge of the object. Detection of the edge by the edge sensor may therefore be achieved by detecting the actual edge 10-2 of the object or a feature on the block a known offset from the edge 10-2 of the object. In some embodiments the apparatus may determine the corner position without the use of a lead or end block. For example, the roller moved to contact the edge 10-1 of the object. The apparatus may comprise a leading edge sensor and a trailing edge sensor. The roller is initially driven in a 'reverse' direction towards a lead portion of the edge 10-1 until the trailing edge sensor detects the second edge 10-2. Preferably the lead portion of the first edge provides a linear or straight path for the roller to move along. The corner lOcl position is calculated based on detection of the second edge 10-2, the tracked position of a component on the chassis (such as the roller C axis) and the known offset or relative positions of the roller and trailing edge sensor. The roller is then driven in a 'forward' direction towards an end portion of the edge 10- 1 until the leading edge sensor detects the third edge 10-3 (the second 'second edge' 10-3). Preferably the end portion of the first edge provides a linear or straight path for the roller to move along. The corner 10c2 position is calculated based on detection of the second edge 10-3, the tracked position of a component on the chassis (such as the roller C axis) and the known offset or relative positions of the roller and leading edge sensor.

Once the edge band has been applied to the first edge, the overlapping portions of tape and the lead and end portions of the edge are trimmed (as described below). Once trimmed the roller may be moved, for example by the X and Y motors in positional mode to place the roller in position to commence an edge banding or other edge modification process to the third edge 10-3. At this stage of a complete edge banding operation, for ease of reference the third edge 10-3 becomes the 'first edge', the first edge 10-1 becomes the 'second edge', and the second edge 10-2 becomes the second 'second edge'. The banding operation is then repeated to provide an edge band to the third edge 10-3. To assist with applying the edge band third edge 10-3 the lead and trailing blocks are arranged at a lead portion and an end portion of the third edge. In the illustrated embodiment, the lead and end blocks 171 and 172 will be aligned since the third edge is linear.

Once the edge band has been applied to the third edge 10-3, the overlapping portions of tape and the lead and end portions of the edge are trimmed (as described below). Once trimmed the roller may be moved, for example by the X and Y motors in positional mode to place the roller in position to commence an edge banding or other edge modification process to the second edge 10-2. At this stage of a complete edge banding operation, for ease of reference the second edge 10-2 becomes the 'first edge', the third edge 10-3 becomes the 'second edge', and the first edge 10-1 becomes the second 'second edge'. The banding operation is then repeated to provide an edge band to the second edge 10-2. To assist with applying the edge band second edge 10-2 the lead and trailing blocks are arranged at a lead portion and an end portion of the second edge. In the illustrated embodiment, the lead and end blocks 171 and 172 will be aligned since the second edge is linear.

The above process is provided by way of example. It is to be understood that the edges (e.g. edges 10-1, 10-2, 10-3) of an object may be banded in any order.

The apparatus may comprise other sensors to assist the controller achieve a successful edge modification operation. For example, the apparatus may comprise an object sensor 212 shown in Figures 5 to 7. When the roller is moved towards the object, the object sensor 212 detects the object and switches the first and second motors 130, 132 into torque control mode. The illustrated embodiment also has a sequence sensor 214 (Figure 5) to detect slots (216 in Figure 7) in the end block 172 to indicate to the controller when to cut the edge band with cutter 300.

Overhanging tape trimmer device

The illustrated embodiment comprises a trimmer assembly to trim the overhanging portions of tape 101 that extend beyond each end of an edge of the object following an edge banding operation along that edge, for example as shown in Figure 8. A trimmer assembly is now described with reference to Figures 11 to 19.

Figures 11 and 12 show a trimmer assembly 180 for trimming the overlapping portions of tape. The trimmer assembly comprises a trimmer head 182 movable horizontally between a parked or non-use position show in Figure 11 and an operational position shown in Figure 12. The trimmer head is also shown in the parked position in Figures 13 to 15. In the illustrated embodiment the trimmer assembly comprises a rail 184. The trimmer head 182 is mounted on the rail 184 to move along the rail between the parked and operational positions. The assembly 180 comprises an actuator such as cylinder 183 to move the head between the parked and operational positions. Other arrangements may be provided to move the head between the parked and operational positions.

In the illustrated embodiment the rail 184 is mounted to the frame 124. As described above, the chassis 120 is also mounted to the frame 124. Therefore, the trimmer head 182 is located at a fixed offset from the roller axis (the C axis) in the X direction in the apparatus coordinate system. The trimmer head 182 is moveable along the rail 184 in the Y direction between the parked and operational positions. Rail 184 is parallel to rails 112. In an alternative embodiment, the trimmer assembly 180 may be mounted to the carriage to be positioned at a fixed offset from the roller axis in the Y direction in the coordinate system. The head 182 would be movable on a rail in the X direction between a parked position and an operational position.

In the parked position, the trimmer head 182 is located away from the chassis 120 so that the trimmer head 182 does not interfere with the chassis 120 and components mounted on the chassis during an edge modification operation. In the parked position, the chassis 120 can rotate a full 360 degrees on the C axis without hitting the trimmer head 182.

The trimmer head has a cutting bit or tool bit 181 to cut the tape 101 to trim off the overlapping length of tape. A motor 185 is provided to drive rotation of the rotary tool bit 181. The trimmer head comprises an actuator 186 to rotate the bit about a vertical axis 190. The illustrated embodiment has a servo 186 to rotate the bit about the vertical axis 190. The bit is rotated about the vertical axis 190 to position the bit in a desired orientation relative 181 to the edge of the object to cut the tape.

The trimmer head 182 comprises an edge sensor to detect an edge of the object. In the illustrated embodiment the sensor is a contact sensor or tracer shoe 187 to make contact with an edge of the object to position the head 182 accurately relative to the object. As described above, the bit 181 is rotatable about a vertical axis 190. The sensor/tracer shoe 187 may be on the vertical axis 190 so that the bit 181 is rotatable about the sensor/tracer shoe 187. The vertical axis may be part way between the tracer shoe and the end of the bit. The bit and tracer shoe may be rotatable together about the vertical axis 190. The bit 181 is in a fixed relation to the edge sensor in the coordinate system, i.e. the bit 181 is at a fixed offset from the trimmer edge sensor 187 in the coordinate system. Where the bit 181 is a rotary bit the bit may have a diameter equal to a width of the tracing shoe. The bit 181 is aligned with the sensor 187 so that the bit extends radially from the sensor 187.

The trimmer assembly comprises an actuator 188 to move the trimmer head in a vertical direction. The actuator moves the trimmer head 182 in the vertical direction (for example on vertical rail 189) to move the bit 181 vertically from above the object to below the object in a cutting operation to trim the overlapping portion of tape from the object.

The bit 181 and the trimmer head edge sensor 187 are pivotable about a vertical pivot point 191. The vertical pivot point 191 is offset from and parallel to the vertical axis 190. In the illustrated example, with reference to Figure 12, the bit 181, bit drive motor 185, and the trimmer edge sensor 187 are mounted to a lower member 194. The lower member is mounted to an upper member 195 by pivot pint 191. The upper member is mounted to the rotary actuator 186.

The bit 181 and trimmer edge sensor 187 and associated components are pivotable about the pivot point 191 to pivot from an aligned position to a first offset position, and from the aligned position to a second offset position. In the aligned position the trimmer edge sensor is aligned with the vertical axis 190 and the bit is rotatable by the rotary actuator 186 about the vertical axis 190 as described above. In the aligned position, the rotary actuator 186 drives rotation of the upper member, lower member and connected components including the trimmer edge sensor 187 and the bit 181 about the vertical axis 190 with the trimmer edge sensor 187 positioned on the vertical axis 190. Other arrangements may be provided to move the trimmer edge sensor 187 from the aligned position to the first and/or second offset positions.

In the first offset position the bit and edge sensor are moved to position the trimmer edge sensor 187 to be offset to a first side of the vertical axis 190. In the second offset position the bit and edge are moved to position the trimmer edge sensor 187 to be offset to a second opposite side of the vertical axis 190. When in the first or second offset position the trimmer edge sensor 187 is a small distance from the aligned position, for example l-3mm.

The trimmer head comprises at least one actuator to move the bit 181 from the aligned position to each of the first and second offset positions. In the illustrated embodiment the trimmer head comprises (refer Figures 11 and 12) a first actuator 192 to move the bit 181 from the aligned position to the first offset position, and a second actuator 193 to move the bit 181 from the aligned position to the second offset position. The first and second actuators 192, 193 are for example cartridge pneumatic cylinders. The actuators 192, 193 are mounted to the lower member 194.

Operation of the trimmer assembly to trim the overhanging portions of tape is now described with reference to Figures 13 to 22.

Figure 13 shows the trimmer head in the parked position at the beginning of an edge banding operation with the roller 202 positioned against lead block 171, as described above. Figure 14 shows the trimmer head in the parked position at the end of an edge banding operation with the roller 202 positioned against end block 172, as described above. Once the edge band has been applied to an edge of the object, the first and/or second motor 130, 132 are switched from torque control mode to position control mode and the chassis is driven by the first and second motors to move the chassis and therefore roller assembly 200 away from the object. The chassis is raised from the lowered position to the raised position by actuator 114 (Figure 15). Figure 15 shows the chassis moved to be positioned away from the object and in the raised position. The chassis drive may also rotate the chassis on the C axis to ensure the chassis is out of the way of the trimmer head when moving from the parked position to the operational position this allows the trimmer head to be optimally positioned to ensure that the trimmer head has maximum coverage over the bed without having to make extra travel in X and Y directions.

Figures 14 and 15 show the trimmer head 182 in the parked position. The trimmer head 182 is moved from the parked position to the operational position shown in Figure 16, by movement along rail 184. In the operational position, the trimmer head 182 is at the same Y position as the roller 202 rotational axis. Thus, in the operational position the trimmer head has the same Y coordinate as the roller and an X coordinate that is offset from the X coordinate of the roller.

The trimmer head 182 is operated to rotate the bit 181 (and bit drive motor 185) by actuator 186 around the vertical axis 190 to a trimming orientation to be oriented relative to the edge of the object in a position to cut the tape at the corner of the object. Figure 17 shows the trimmer head rotated about the vertical axis 190 to the trimming orientation. The bit may be rotated around the vertical axis 190 to the trimming orientation simultaneously as the trimmer head moves along rail 184 from the parked position to the operational position.

For example, with the object arranged with its first edge parallel to the X axis, the chassis orientation sensor may be calibrated to provide an angle of 0 degrees with the chassis oriented to position a line drawn between the sensor 210 and the C axis perpendicular to the edge of the object. The controller is configured to determine that for a chassis angle of 0 degrees the first edge is parallel to the X axis (at 0 degrees to the X axis). For a chassis angle of for example 30 degrees, the controller can determine the angle of the first edge in the coordinate system is 30 degrees to the X axis

As described earlier, the apparatus is configured to rotate the chassis to orient the chassis to the edge so that the edge sensor 210 is in a known offset position to the roller and also a known orientation (angle) relative to the edge of the object. The apparatus has a sensor in communication with the controller to detect an angular orientation of the chassis, for example an encoder on the chassis drive motor as described earlier. In some embodiments, the controller determines the trimming orientation for the bit 181 based on the angular position of the chassis. For example, with the first edge parallel to the X axis in the coordinate plane, the chassis is oriented in an angular orientation of 0 degrees and a line between the edge sensor 210 and the roller axis is perpendicular to the object edge. The controller orientates the cutting bit 181 to an angular position of 0 degrees to place the cutting bit in a correct cutting position to trim the edge tape at a 90 degree corner, so that the tape is cut flush with the second edge.

For an object corner angle other than 90 degrees, the controller orientates the trimmer head to the same angle as the chassis angle plus a transform value. For example, where the chassis orientation is measured in a clockwise direction, for an angle less than 90 degrees at the leading portion of the first edge, the controller rotates the trimmer bit (and trimmer edge sensor) to an angle equal to the chassis angle plus the corner angle plus 270 degrees. The transform value is equal to the corner angle plus 270 degrees. For a corner angle greater than 90 degrees, the controller rotates the trimmer bit (and trimmer edge sensor) to an angle equal to the chassis angle plus the corner angle minus 90 degrees. The transform angle is equal to the corner angle minus 90 degrees. For example, for a corner angle of 60 degrees, the trimmer is rotated to an angle of 330 degrees to cut the tape flush with the second edge. For a corner angle of 120 degrees, the trimmer is rotated to an angle of +30 degrees to cut the tape flush with the second edge. A similar calculation may be performed to determine the angle to orientate the trimmer at the corner at the end portion of the first edge. The controller may determine if an object corner is at the leading portion or trailing portion of the first edge by the edge sensor 210 detecting a rising edge of the object (at the leading portion of the first edge) or a falling edge of the object (at the trailing portion of the first edge).

As described earlier the controller has calculated the position of the corner of the object in the coordinate system when modifying the edge of the object (i.e. when applying the edge band). Alternatively, the controller has calculated the position of a point on the second edge at an offset from the corner. With the trimmer edge sensor 187 in the aligned position on the vertical axis 190 of the trimmer head, the controller operates the first and second motors to move the carriage on longitudinal rails 110 and the frame on transverse rails 112 to position the trimmer edge sensor 187 at the second edge 10-2/10-3 of the object 1 adjacent the known corner position 10cl/10c2 of the object. This position is shown in Figure 18. As described above, in some embodiments, the controller determines a position in the coordinate system on the second edge 10-2 that is offset from the corner of the object by a known offset distance.

For example, the controller determines the point on the second edge detected by the sensor assembly edge sensor 210. In some embodiments, the controller positions the trimmer at the corner of the objection by positioning the trimmer edge sensor 187 at the point on the second edge previously determined by the controller. In some embodiments, the controller positions the trimmer at the corner of the objection by positioning the trimmer edge sensor 187 at the point on the second edge detected by the sensor assembly edge sensor.

The controller operates the actuator 192, 193 to move the trimmer edge sensor 187 from the aligned position on the vertical axis 190 to either the first offset position or the second offset position, depending on whether the trimmer is trimming the tape at the lead portion or the end portion of the edge 10-1. When in the first or second offset position, the trimmer head is lowered by the actuator 188 until the edge sensor 187 is adjacent the second edge 10-2 of the object, as shown in Figure 19. The illustrated embodiment includes a distance or object thickness sensor 196 (Figure 22 to determine a height at which the edge sensor 187 is adjacent the second edge 10-2 of the object but with the cutting bit 181 positioned above the object.

The distance/thickness sensor 196 is offset from the contact sensor 187 to detect the top surface of the object or block 171, 172 to ensure the contact sensor is adjacent the edge before moving the sensors 187 to the aligned position to contact the edge so the bit is mechanically controlled to cut the tape flush with the second edge.

The actuator 192, 193 then moves the edge sensor 187 to contact the second edge 10-2 with the bit 181 positioned above the edge band 101 as shown in Figures 20 and 21. The actuator continues to drive the bit downwards from above the object to below the object with the edge sensor 187 sliding against the second edge to accurately position the bit 181 to cut the tape flush with the corner and second edge 10-2 of the object. Once the bit has traversed vertically to below the tape the overhanging portion of tape has been cut from the object. The actuator may then move the trimmer edge sensor 187 and the bit 181 to position the edge sensor to the first or second offset position to be clear of the second edge 10-2 of the object. The controller may lift the trimmer head from below the object to above the object, then move the trimmer edge sensor to the aligned position, and then move the trimmer head to the other end of the banded edge 10-1 to cut the overhanging portion of tape at the other end of the edge. Figures 18 to 21 show the trimmer head cutting the overhanging portion of tape from the lead end of the banded edge 10-1. Figure 22 shows the trimmer head positioned to cut the overhanging portion of tape at the trailing end of the banded edge 10-1.

In some embodiments the trimmer head may be moved from above the object to below the object with the trimmer in the offset set position, and then move the trimmer bit to the aligned position and then move the trimmer from below the object to above the object to trim the tape flush with the second edge. For a rotary trimmer tool bit 181, preferably the 'flush-cut' is made with the rotation of the bit 181 against the second edge in the direction of travel up or down the edge.

The trimmer head 182 may also have a slot sensor 197 (Figure 22 as a safety measure. If the trimmer head has been moved to the corner location but the slot sensor does not detect the slot then the controller stops the edge modification process at the corner to prevent damage to the object.

Once both ends of a banded edge 10-1 have been trimmed, the trimmer head 182 may be returned to the raised and parked position, for example as shown in Figure 15. The controller may then drive the chassis with the motors 130, 132 in positional control to commence banding of another edge of the object.

The invention has been described by way of example with reference to an edge modification apparatus for applying an edge band to an edge of an object including trimming overhanging portions of the edge band at the corners of the object. However, the invention may be applied for other purposes as described earlier.

The trimmer assembly is a tool assembly to provide an edge modification process to or at a corner of the object. The tool assembly has a tool head 182 with tool bit 181 movable vertically on rail 184.

In the illustrated embodiment a drive mechanism moves both the chassis and the tool assembly in the coordinate system. The first and second motors 130, 132 provide the drive mechanism to move both the chassis and the tool assembly in the coordinate system.

The chassis carrying the roller is or comprises a primary or first tool to provide a primary or first edge modification process along the edge of the object and the trimmer assembly is or comprises an auxiliary or second tool assembly to provide an auxiliary or second edge modification process to or at a corner of the object. The location of the corner for the second edge modification process is determined during the primary edge modification process performed by the primary tool. In the illustrated embodiment a drive mechanism moves both the primary tool and the auxiliary tool in the coordinate system. The first and second motors 130, 132 provide the drive mechanism to move both the primary tool and the auxiliary tool in the coordinate system. In the illustrated embodiment the primary tool comprises the pressure roller for applying pressure to an edge band to the edge of the object, however the cutter assembly may also be considered a primary tool. The auxiliary tool comprises the trimmer head with cutting bit for trimming the overhanging portion of tape. In a further example, the primary tool comprising a roller may apply a paint or other coating to the edge and the auxiliary tool may comprise a tool to cut, sand, grind or place a component at or to a corner of the object. In an alternative embodiment the roller 202 simply traces the edge of the object to determine the corner positions to locate the tool assembly to the corners of the object.

The invention provides a significant advantage over more complex prior art machines such as by CNC machines. An apparatus according to the present invention allows for the set up and running of complex shaped components to be much simpler than the programming required to process complex shaped components in a CNC set up. Manufacturing becomes very flexible as different shaped objects can be mounted to the bed one after the other without having to reprogram the apparatus on each change of object shape. With contour processing (e.g. contour edge banding) on CNC machines, a lot of set up time is required by a skilled CNC programmer, which makes single runs impractical from a time and cost perspective. In an apparatus according to the present invention, an operator does not need to be a person with specialised CNC programming skills. An operator simply mounts the object to the bed and sets a start position for the roller at a distance from the first edge or start block. Depending on the embodiment, the operator may also enter a corner angle for the corner at each end of the edge being banded. The apparatus then automatically carries out the edge modification including modification at the corners without further programming.

The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims.