Cross-Reference to Related Applications [0001] The present application claims the benefit of U.S. Provisional Patent Application Serial No. 63/149,191 filed February 12, 2021 and titled “ROTARY VENEER CLIPPER MONITORING/CONTROL SYSTEM,” the entire disclosure of which is hereby incorporated by reference herein.

Technical Field

[0002] Embodiments described herein relate to the field of wood veneer production, and, more specifically, to systems, methods, and apparatuses for monitoring/controlling rotary veneer clippers.

Background

[0003] The production of wood veneer from softwood logs typically involves conveying the logs in succession through a debarker, cutting the logs into shorter sections (block) of desired lengths, and scanning each block to determine an optimal rotational axis for that block. The block is then transferred to a rotary lathe that spins the block about the optimal rotational axis while pressing a knife edge against the outer surface of the block to peel the block into a continuous or semi-continuous ribbon of veneer of a desired thickness and a width that generally corresponds to the length of the block. For example, wood veneer that is to be used in 4’ x 8’ sheets of plywood is typically peeled from blocks that are about 102” in length, and the blocks are peeled to produce ribbons of veneer that are about 1/8” thick and about 102” wide along at least part of their lengths. In any case, the block is spun and peeled until the diameter of the block reaches a minimum diameter (e.g., 2-4”). The remaining portion of the block (the ‘core’) is removed from the lathe and the next block is inserted for peeling.

[0004] As the ribbon of veneer is peeled from the block, it is conveyed along a path of flow through various processing stations. Typically, the ribbon is moved on a belt conveyor through a scan zone upstream of a clipper. A camera captures images of the ribbon as it moves through the scan zone. An optimization computer processes the images to identify defects such as bark, voids, splits, and knots, and determines where the ribbon should be cut to meet various criteria (e.g., to maximize monetary value and/or wood recovery, to fill orders for particular products, rules established by the mill, etc.).

[0005] After scanning, the ribbon proceeds to the clipper. Rotary veneer clippers typically include an upper anvil roll and a lower anvil roll that extend across the path of veneer travel. A double-edged knife extends between, and parallel to, the rotational axes of the anvil rolls. The vertical distance between the upper anvil roll and the lower anvil roll is slightly less than the width of the knife. The knife is rotatable from a starting position, in which the knife is in a generally horizontal orientation (i.e., with the cutting edges lying within a generally horizontal plane), to a cutting position, in which the knife is in a generally vertical orientation. The anvil rolls are coated in an elastic or compressible material, such as rubber or urethane, to act as anvils for the knife.

[0006] As the ribbon of veneer passes over the lower anvil roll and below the knife, a control system rotates the knife to clip the ribbon. Rotation of the knife to the vertical cutting position brings one of the cutting edges into contact with the upper anvil roll and the other cutting edge into contact with the veneer. The veneer is pinched between the cutting edge and the bottom anvil roll until the cutting edge passes through the thickness of the ribbon and into contact with the outer surface of the bottom anvil roll, severing a piece of veneer from the remainder of the ribbon. [0007] Ideally, the knife speed should match the roll speed to minimize the wear of the upper and lower anvil roll coating. Speed mismatch causes a small amount of the coating material to be removed from one or both anvil rolls each time the knife makes a clip. Speed mismatch can also affect clip quality. The diameters of the anvil rolls decrease over time due to wearing and speed mismatch. Once the anvil roll diameter is below a given threshold, indicating that much of the coating on the anvil roll has worn away, the roll must be recoated or replaced. For example, an anvil roll that has a total diameter of 11”, including a coating about 1-1.5” thick, might require recoating or replacement when the diameter of the anvil roll has been reduced to 9”. The typical service life of clipper anvil rolls is about 3-6 months.

[0008] Prior control systems for rotary veneer clippers controlled the clipper based on the surface speeds and diameters of the anvil rolls. In earlier systems, anvil roll surface speeds were measured manually and input (e.g., via keyboard) by mill personnel. More recent control systems use feedback from measuring devices to calculate the surface speeds of the anvil rolls. Each measuring device has an encoder and a measuring wheel mounted to a common shaft, and the measuring wheel rides continuously on the respective anvil roll. The rotation of the anvil roll drives the rotation of the measuring wheel and the shaft, the encoder detects the rotation of the shaft. However, these control systems still relied on manual measurement and input of anvil roll diameter by mill personnel to control the veneer clipper.

Brief Description of the Drawings

[0009] Embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings. Embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.

[0010] Figure 1 is a perspective view of a measuring device;

[0011] Figures 2A-B are perspective and side elevational views, respectively, of a base for a measuring device as shown in Fig. 1 ;

[0012] Figures 2C-D are perspective and side elevational views, respectively, of a support arm for a measuring device as shown in Fig. 1 ;

[0013] Figure 3 is a rear elevational view of the measuring device of Fig. 1 ;

[0014] Figure 4 is a sectional view taken along lines A — A of Fig. 3;

[0015] Figures 5A, 5B, and 5C are schematic views that illustrate corresponding positions of the measuring device of claim 1 ;

[0016] Figures 6A-B are schematic views of a second embodiment of a measuring device;

[0017] Figure 7 is a schematic view of a third embodiment of a measuring device;

[0018] Figure 8 is a schematic view of a fourth embodiment of a measuring device;

[0019] Figures 9A and 9B are front and rear perspective views, respectively, of a rotary veneer clipper with measuring devices;

[0020] Figure 10 is a front elevational view of the rotary veneer clipper of Figs. 9A and 9B and a control system;

[0021] Figure 11 A is a rear elevational view of the rotary veneer clipper of Figs. 9A-B;

[0022] Figure 11 B is a sectional view taken along lines A — A of Fig. 11 A; [0023] Figure 12 is a schematic view of a control system for a rotary veneer clipper with measuring devices;

[0024] Figure 13 is a flow diagram of a method of measuring an anvil roll;

[0025] Figure 14 illustrates a processing routine for determining the diameter of an anvil roll;

[0026] Figure 15 illustrates an example of a corresponding user interface;

[0027] Figure 16 illustrates an example of a controller configured to implement various operations described herein; and

[0028] Figure 17 illustrates and example of an operator interface configured to implement various operations described herein, all in accordance with various embodiments.

Detailed Description of Disclosed Embodiments [0029] In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

[0030] Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments; however, the order of description should not be construed to imply that these operations are order dependent.

[0031] The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of disclosed embodiments.

[0032] The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other. [0033] For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” means (A), (B), or (A and B). For the purposes of the description, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C). For the purposes of the description, a phrase in the form “(A)B” means (B) or (AB) that is, A is an optional element.

[0034] The description may use the terms “embodiment” or “embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous.

[0035] As used herein, the terms “non-transitory computer-readable medium” and “non-transitory computer-readable media” encompass all computer-readable media except for a transitory, propagating signal.

[0036] In exemplary embodiments, a computing device may be endowed with one or more components of the disclosed apparatuses and/or systems and may be employed to perform one or more methods as disclosed herein.

[0037] The above-noted prior control systems and measuring devices have a number of disadvantages.

[0038] First, manual measurements of anvil roll surface speed and anvil roll diameter are time-consuming and may be inaccurate. Using the prior measuring devices reduces the need for manual measurements of the anvil roll surface speeds. However, the constant pressure of the measuring wheel against the anvil roll tends to wear a groove in the surface of the roll, causing premature wearing of the anvil roll. And because the diameter of the anvil roll within the groove is less than the diameter outside of the groove, the surface speed of the roll within the groove is less than the surface speed outside of the groove, resulting in an inaccurate measurement of surface speed. As the groove deepens, the accuracy declines even further. Once the groove has reached a certain depth, the anvil roll must be recoated or replaced. As such, the use of the prior measuring wheel may reduce the useful service life of the anvil roll and necessitate more frequent replacement or recoating of the anvil roll.

[0039] The continuous contact between the measuring wheel and the outer surface of the anvil roll can also cause pitch buildup on, and/or accelerate wearing of, the contact surface of the measuring wheel. This can also reduce the accuracy of the measurements of anvil roll surface speed.

[0040] In addition, in prior control systems used with the above-noted measuring devices, motion commands are driven from the measuring wheel encoder feedback axis. When the encoder fails, the control system lacks the data it requires to control the clipper. As a result, veneer processing through the clipper must be halted and the measuring wheel encoder must be replaced before resuming operation of the clipper, unless the system can be run in “open loop” mode by ignoring the measuring wheel encoders. Moreover, because the measuring wheel rides continuously on the anvil roll, the measuring wheel encoder tends to wear quickly and is prone to failure. The resulting downtime can be costly to the mill. [0041] Embodiments of systems, methods, and apparatuses described in the present disclosure may help to reduce or alleviate some or all of the above-noted disadvantages.

[0042] In various embodiments, a measuring apparatus may include a measuring wheel, a rotation sensor (e.g., a rotary encoder or other sensor configured to detect rotation) operatively coupled with the measuring wheel, and means for moving the measuring wheel between a resting position and a measuring position. The measuring wheel and the rotation sensor may be mounted to a shaft. The means for moving the measuring wheel may include an actuator, and the shaft may be rotatably coupled to the actuator. The actuator may also be mounted to a support. The actuator may be selectively operable to move the shaft, relative to the support, between a retracted or resting position and a measuring position.

[0043] In some embodiments, the measuring apparatus may further include a support arm. The shaft may be rotatably mounted to the support arm. The actuator may be coupled to a first portion of the support arm and to the support, such that the actuator is selectively operable to move the support arm relative to the support. Optionally, a second portion of the support arm may also be movably mounted to the support.

[0044] In some embodiments, the measuring apparatus may further include a base. The base may be, or may include, a bracket or other mechanical fastener configured to be mounted to the support. The base may have coupling features configured to connect a first portion of the actuator and a first portion of the support arm to the base at respective locations. A second portion of the actuator may be connected to a second portion of the support arm and/or the shaft.

[0045] In a particular embodiment, the measuring apparatus has a base, a support arm, a shaft, and a measuring wheel and a rotary encoder mounted to the shaft. The base is generally angular and/or curved in cross-section, with a first portion and a second portion that meet at a middle portion and define respective ends. The support arm has a first end, a second end, and a middle portion. Optionally, the support arm may also be generally angular and/or curved in cross- section. The first end of the support arm is pivotably coupled to the second portion of the base, such that the support arm is pivotable about a first pivot axis relative to the base. The first portion of the base and the second end of the support arm are pivotably coupled to opposite first and second ends, respectively, of a linear actuator. The shaft is rotatably mounted to the support arm and oriented generally parallel to the first pivot axis. The linear actuator is selectively extendable and retractable to pivot the support arm about the first pivot axis in opposite rotational directions to thereby move the measuring wheel to the resting position and the measuring position. Optionally, the base may be configured to be fixedly coupled to a support surface, such as a frame of a veneer clipper.

[0046] In various embodiments, a veneer clipper system may include a frame, an upper anvil roll and a lower anvil roll rotatably coupled to the frame, and at least a first measuring apparatus as described herein. The first measuring apparatus includes a measuring wheel operatively coupled with a rotation sensor and means for moving the measuring wheel to a measuring position, in which the measuring wheel is in contact with one of the anvil rolls, and a resting position in which the measuring wheel is not in contact the anvil roll. Optionally, the veneer clipper system may further include a servo motor operatively coupled with the anvil roll. The servo motor may include a rotation sensor, such as a multi-turn absolute encoder. [0047] In various embodiments, a veneer clipper control system may include one or more computers configured to determine a diameter of the anvil roll based at least in part on signals received from the encoder of the measuring apparatus and signals from an encoder positioned to detect rotation of the anvil roll shaft or the shaft of a motor that drives the anvil roll in rotation. For example, if the anvil roll is driven by a servo motor, the control system may be configured to determine the diameter of the anvil roll based in part on signals received from the servo motor encoder. Optionally, the control system may be configured to determine an estimated wear value for the anvil roll based on the determined diameter and an initial or ideal anvil roll diameter.

[0048] In various embodiments, a method of upgrading a veneer clipper may include operatively coupling a measuring apparatus with the veneer clipper. Optionally, the method may further include operatively coupling the measuring apparatus with a control system as described herein.

[0049] In various embodiments, an upgrade kit for a veneer clipper may include a measuring apparatus and/or a control system as described herein.

[0050] Referring now to the Figures, an embodiment of a measuring apparatus 100 and components thereof is shown by way of example in Figs. 1 and 2A-D. In this embodiment, measuring apparatus 100 includes a base 110, a support arm 120, a shaft 130, a measuring wheel 140, a rotation sensor 142, and an actuator 146.

[0051] Rotation sensor 142 is configured to detect rotation of the shaft and provide feedback that represents the detected rotational movement. Typically, rotation sensor 142 is a rotary encoder configured to convert the angular position of the shaft into an analog or digital feedback signal. However, rotation sensor 142 may be any other type of sensor suitable for use to detect and report rotation of the shaft (e.g., an angle encoder, a magnetic rotary position sensor, a resolver, etc.). [0052] Base 110 may be configured to connect the other components of the measuring apparatus 100 to a support, such as a beam, a platform, or a frame of another machine (e.g., a clipper device, a conveyor, etc.) Base 110 may have multiple parts that are connected by bolts, welds, and/or other fasteners.

Alternatively, base 110 may be formed from a single piece of material, such as steel or other rigid material.

[0053] In some embodiments, base 110 may be generally angular in cross- section, with a first portion 102 and a second portion 104 that meet at an angle to form a middle portion 106. The second portion 104 may have, or may be, a pair of arm portions 104a and 104b that extend generally parallel to one another on opposite sides of the base 110.

[0054] Base 110 may include one or more coupling features configured to movably connect the support arm 120 and/or the actuator 146 to the base. For example, the first portion 102 of the base 110 may have a first coupling feature configured to connect a first end of the actuator 146 to the base 110, and the second portion 104 of the base 110 may have a second coupling feature configured to connect the support arm 120 to the base 110. Optionally, the first and second coupling features may be located at or near the free ends of the first and second portions, respectively, of the base. In some embodiments, as shown for example in Figs. 1 and 2A-B, the first coupling feature may be a pivot bracket 108a with a pivot pin 148a located along the first portion 102 of the base 110, and the second coupling feature may be a pair of annular bearings 108a and 108b disposed in corresponding apertures of arm portions 104a and 104b, respectively, and a pivot pin 108c disposed through the bearings. Thus, in those embodiments the first coupling feature may be a first pivot bracket, and the second portion 104 of the base 110 and the second coupling feature may collectively form a second pivot bracket. However, the types and locations of the coupling features vary among embodiments. For example, in some embodiments the second coupling feature may be a pivot bracket or other mechanical fastener coupled to the second portion of the base.

[0055] Support arm 120 may have a first end 120a, a second end 120b, and a middle portion. Support arm 120 may also have a first coupling feature 124 located at the first end, a second coupling feature 126 located at the middle portion, and a third coupling feature 128 located at the second end. The coupling features may be through-holes, brackets, or other mechanical features that define respective pivot axes. Optionally, support arm 120 may be generally angular and/or curved in cross- section.

[0056] In some embodiments, as shown by way of example in Figs. 2C-D, support arm 120 includes a first arm portion 122a, a second arm portion 122b, and a transverse portion 122c. The first and second arm portions 122a and 122b may be generally planar, each having inner and outer faces connected by an outer edge.

First and second arm portions 122a, 122b may be oriented generally parallel to one another and spaced apart by a gap between the respective inner faces. The arm portions may be rigidly connected by the transverse portion 122c. Optionally, transverse portion 122c may be extend along respective portions of the outer edges of the arm portions. Alternatively, transverse portion 122c may be an elongated bar or cylinder that extends between the inner faces of the arm portions 122a or 122b, or any other suitable means for rigidly connecting the arm portions together. [0057] In the illustrated embodiment, the first coupling feature 124 includes through-holes 124a and 124b that extend through the faces of first and second arm portions 122a and 122b, respectively, at the first end of the support arm 120. The second coupling feature 124 includes through-holes 124a and 124b that extend through the faces of first and second arm portions 122a and 122b, respectively, at the middle portion of the support arm 120. The third coupling feature 128 is a through-hole that extends through the faces of the first arm portion 122a. In this embodiment, the second arm portion 122b is shorter than the first arm portion 122a, and first arm portion 122a forms the second end of the support arm 120. Alternatively, the first and second arm portions could have the same length and shape. In that case, the second arm portion may optionally have a corresponding through-hole or other coupling feature at the second end of the support arm 120. Alternatively, in other embodiments, support arm 120 may include only one arm portion (e.g., first arm portion 122a), and the other arm portion (e.g., second arm portion 122b) and/or the transverse portion 122c may be omitted.

[0058] Shaft 130 may be rotatably mounted to the support arm 120. In some embodiments, the second coupling feature 126 includes through-holes 126a and 126b, and the shaft 130 is disposed through the through-holes 126a and 126b with the shaft oriented substantially perpendicular to the faces of the arm portions 122a and 122b.

In other embodiments the second coupling feature 126 may be one or more rotary bearings mounted to the support arm 120 and the shaft 130 may be rotatably mounted to the support arm 120 by the rotary bearings.

[0059] Measuring wheel 140 and rotation sensor 142 may be coupled to shaft 130. In some embodiments, as best shown in Figs. 1 and 3, measuring wheel 140 and rotation sensor 142 may be disposed on opposite sides of support arm 120, or on opposite sides of a portion of support arm 120 (e.g., first arm portion 122a). Optionally, rotation sensor 142 may be coupled to the support arm 120 by a bracket 144. Typically the measuring wheel is fixedly mounted to the shaft with the measuring wheel and the shaft in axial alignment. However, the measuring wheel may instead be coupled to the shaft in an ‘off axis’ position by a belt, gears, or the like. Regardless, the measuring wheel is coupled to the shaft such that the shaft is driven in rotation by rotation of the measuring wheel. [0060] The first end of the support arm 120 may be movably coupled to the base 110. In some embodiments, the support arm 120 is pivotably coupled to the base 110 by a pivot pin 108c that extends through the base and the support arm (e.g., through bearings 108a and 108b and through-holes 124a and 124b). Alternatively, the first end of the support arm 120 may be pivotably coupled to the base 110 by any other suitable means.

[0061] In various embodiments, the actuator 146 may be a linear actuator with a first end and an opposite second end. The first end of actuator 146 may be pivotably coupled to the first portion 102 of the base 110. The second end of actuator 146 may be pivotably coupled to the second end of support arm 120.

[0062] As best shown in Fig. 4, the first end of actuator 146 may be pivotably coupled to base 110 by pivot bracket 108a and pivot pin 148a. The second end of actuator 146 may be pivotably coupled to the second end of the support arm 120 by a pivot pin 148b. In some embodiments, actuator 146 may be a linear actuator. For example, actuator 146 may be a hydraulic or pneumatic actuator that includes a cylinder 146a (e.g., a hydraulic cylinder or a pneumatic cylinder) and a piston 146b. The second end of actuator 146 may be the free end of piston 146b or a connector 146c coupled to the free end of piston 146b. Alternatively, actuator 146 may be a mechanical linear actuator (e.g., a leadscrew, screw jack, ball screw, roller screw, etc.) or any other suitable type of linear actuator. In either case, pivot pin 148b may be disposed through the second end of actuator 146 and the third coupling feature 128 (e.g., through-hole 128) at the second end of support arm 120.

[0063] Actuator 146 may be selectively operable to extend and retract the piston 146b relative to cylinder 146a to rotate the support arm 120 in respective opposite rotary directions about pivot pin 108c to thereby move the measuring wheel relative to base 110. As shown for example in Figs. 5A-C, extending the piston 146b may rotate the support arm 120 in a first rotary direction to move the measuring wheel along a path of motion 112 from a resting or retracted position, in which the measuring wheel is spaced apart from the veneer anvil roll 52 (Fig. 5A), to a measuring position (Figs. 5B, 5C) in which the measuring wheel is in contact with the anvil roll 52. In the measuring position, the axes of rotation of the measuring wheel and the anvil roll are substantially parallel to one another. Retracting piston 146b relative to the cylinder rotates the support arm 120 in an opposite second rotary direction to move the measuring wheel along the path of motion 112 to the resting position.

[0064] In this configuration, the actuator 146, base 110, and support arm 120 are linked by three pivot joints, and each of the pivot joints defines a respective rotational axis that is substantially parallel to shaft 130. In the illustrated embodiment, the three rotational axes 134, 136, and 138 are defined by pivot pins 148a, 108c, and 148b, respectively (see Fig. 3). The rotational axes 134 and 136 are fixed in location relative to base 110 (or to the support), and the rotational axis 138 moves relative to base 110 (or the support) as actuator 146 rotates the support arm 120.

[0065] In other embodiments, the measuring apparatus 100 may be configured to move the measuring wheel along a linear path of movement, as opposed to an arcuate path of movement. For example, in the embodiments schematically illustrated in Figs. 6A and 6B, the second end of the actuator 146 may be connected (directly or indirectly) to shaft 130 such that the rotational axis of the shaft 130 is perpendicular to, and intersects, the center axis of the shaft 130. Again, the measuring wheel 140 and the rotation sensor 142 are mounted to the shaft 130, and the first end of the actuator is mounted to base 110. In this embodiment, extension of the piston 146b moves the measuring wheel relative to base 110 along a linear path of motion to an extended or measuring position (Fig. 6B), and retraction of the piston 146b moves the measuring wheel relative to base 110 along the linear path to a retracted or resting position (Fig. 6A). Some embodiments of this type may omit a support arm. Other embodiments may include a support arm (e.g., support arm 120 or similar structure). In that case, the shaft 130 may be rotatably mounted to the support arm, and the actuator 146 may be connected to the support arm (Fig. 7). In either case, the measuring apparatus may optionally include one or more guide members 132 (e.g., slide rail, linear bearing, etc.) configured to guide the shaft 130 and/or support arm along the linear path of motion (Fig. 8).

[0066] Other variations are also possible. For example, base 110 may have a different cross-sectional shape than illustrated, such as triangular, planar, U-shaped, or any other suitable shape. Some embodiments of the measuring apparatus 100 lack a base 110. In those embodiments the first end of actuator 146 (and optionally, the first end of support arm 120, if present) may be mounted directly to a support, such as the frame of a veneer clipper, the frame of another piece of equipment (e.g., a conveyor), or another support structure.

[0067] Likewise, the means for moving the measuring wheel may be (or may include) a mechanism other than a linear actuator. For example, actuator 146 could be a rack and pinion mechanism, a conveyor, a set of gears, a rotary actuator, or any other mechanism(s) or device(s) suitable for use to move the measuring wheel into, and/or away from, contact with the respective anvil roll.

[0068] Typically, the path of travel 112 has a first end and an opposite second end, and the retracted position and the measuring position(s) are positions located at or proximal to the first end and the second end, respectively. However, the configuration and/or means for moving the measuring wheel varies among embodiments, and in some measuring devices the path of travel may be circular, elliptical, or otherwise lack opposite ends. For clarity, the term “extended position” is used herein in reference to the position of the shaft or measuring wheel at the second end of the path of travel. In the case of a linear actuator, the extended position is the position of the shaft or measuring wheel when the actuator is extended to its maximum length.

[0069] Preferably, the extension of actuator 146 is halted by the contact between the measuring wheel and the surface of the roll 52. In that case the actuator 146 can be operated to move the measuring wheel to the measuring position regardless of the remaining thickness of the coating layer 52a or the diameter of roll 52. Alternatively, the extension of actuator 146 may be halted or adjusted by a control system in response to received feedback (e.g., from a pressure sensor, optical sensor, or signals from the rotation sensor 142).

[0070] In some embodiments the means for moving the measuring wheel includes one mechanism that is operable to apply force in opposite directions (e.g., push and pull). Examples of such mechanisms include, but are not limited to, pneumatic cylinders, hydraulic cylinders, and screw actuators. In other embodiments, the means for moving the measuring wheel can include a first mechanism that is operable to apply force in one direction (e.g., a single-acting pneumatic or hydraulic cylinder, an airbag, or the like). In that case, the means for moving the measuring wheel may optionally a second mechanism that is operable to apply force in the opposite direction, such as a biasing member (e.g., a mechanical spring). Alternatively, the measuring device may be configured or arranged such that the measuring wheel, shaft, and rotation sensor (and optionally other components) are moved in the opposite direction by gravity.

[0071] In embodiments of the measuring apparatus that do include a linear actuator, the components may alternatively be arranged such that retraction of the linear actuator moves the measuring wheel to the measuring position and extension of the linear actuator moves the measuring wheel to the resting position.

[0072] Preferably, the means for moving the measuring wheel is a mechanism or device that can be controlled remotely and/or automatically. However, this is not essential.

[0073] Thus, a measuring apparatus in accordance with the present disclosure includes a measuring wheel, a rotation sensor operatively coupled with the measuring wheel, and means for moving the measuring wheel between a resting position and a measuring position.

[0074] A measuring apparatus in accordance with the present disclosure may be mounted to the frame of a rotary veneer clipper, or to a support, in an operating position. For clarity, an “operating position” is a position in which the measuring apparatus is located and oriented relative to a corresponding measurement target, such as an anvil roll of the veneer clipper, such that the actuator is operable to move the shaft (and thereby move the measuring wheel) along the path of travel into and/or away from contact with the measurement target.

[0075] In various embodiments, a veneer clipper system may include a pair of anvil rolls mounted to a frame and at least one measuring apparatus that includes a measuring wheel, a rotation sensor operatively coupled with the measuring wheel, and means for moving the measuring wheel between the resting position and a measuring position in which the measuring wheel is in contact with one of the anvil rolls. An embodiment of a veneer clipper system is shown by way of example in Figs. 9A-11 B.

[0076] Referring first to Figs. 9A-B, veneer clipper system 200 includes a frame 250, an upper anvil roll 252a and a lower anvil roll 252b rotatably mounted to the frame 250, a first measuring apparatus 100 operatively coupled with the upper anvil roll 252a, and a second measuring apparatus 100 operatively coupled with the lower anvil roll 252b. For clarity, the first and second measuring apparatuses are indicated in Figs. 9-12 as 100a and 100b, respectively. In this context, each of the first and second measuring apparatuses is ‘operatively coupled with’ the respective one of the anvil rolls in the sense that the measuring apparatus is operable to move the respective measuring wheel into, and away from, contact with the respective anvil roll.

[0077] Each of the measuring apparatuses 100a and 100b includes a measuring wheel 140, a rotation sensor 142 operatively coupled with the measuring wheel 140, and an actuator 146 that is selectively actuable to move the measuring wheel to the resting position, in which the measuring wheel is spaced apart from the anvil roll, and to a measuring position, in which the measuring wheel is in contact with the anvil roll.

[0078] The upper and lower anvil rolls 252a and 252b are mounted on roll shafts 258a and 258b, respectively, and oriented parallel to one another and transverse to the direction of veneer flow.

[0079] As best shown in Fig. 10, upper anvil roll 252a is operatively coupled with motor 254a, and lower anvil roll 252b is operatively coupled with motor 254b. In some embodiments the motors 254a and 254b are positioned off-axis (with the output shaft of the motor transverse to, or offset from, the respective roll shaft). However, in other embodiments one or both of the motors may instead be positioned with the output shaft of the motor in axial alignment with the respective roll shaft. [0080] Preferably, motors 254a and 254b are servo motors with respective rotation sensors (e.g., multi-turn absolute encoders) 268a and 268b (see Fig. 12). Alternatively, motors 254a and 254b may be another type of motor. If motors 254a and 254b do not include rotation sensors rotation sensors 268a and 268b may instead be operatively coupled to the output shafts of the motors and/or to the anvil rolls (e.g., coupled to the roll shafts).

[0081] Optionally, the motors 254a and 254b may be connected to respective gear reducers 256a and 256b. In the illustrated embodiment, the motors 254a and 254b are brushless servo motors with multi-turn high resolution absolute encoders (e.g., Allen-Bradley MP-Series low inertia servo motors) and are supported on respective platforms that are mounted to the frame 252. The motors are connected to respective gear reducers 256a and 256b, which are operatively coupled with the respective roll shafts by respective drive belts. The anvil rolls have an initial or ideal diameter of 11 inches, and the gear reducers have a gear reducer ratio of 11 :1. However, the diameter of the anvil rolls and the reduction ratio of the gear reducers (if present) may vary among embodiments. [0082] A double-edged knife 260 (Fig. 10) extends between, and parallel to, the upper and lower anvil rolls. The width of the knife from edge to edge is slightly less than the vertical distance between the upper anvil roll and the lower anvil roll. The knife 260 is connected at opposite edges to motors 262a and 262b, which may also be mounted to frame 250. Motors 262a and 262b are selectively operable to rotate the knife 260 to a generally horizontal starting position and to a generally vertical cutting position, in which the cutting edges of the knife are against the upper and lower anvil rolls 252a and 252b.

[0083] The measuring apparatuses 100a and 100b are mounted in respective operating positions relative to the corresponding anvil rolls. The measuring apparatuses may be mounted to the frame 250 of the veneer clipper, or to a platform, beam, or other such article that is mounted to the frame 250. For example, the frame 250 may include an upper support member 264a located above the flow path and a lower support member 264b located below the flow path. The first measuring apparatus 100a may be mounted to the upper support member 264a and the second measuring apparatus 100b may be mounted to the lower support member 264b. While the measuring apparatuses are shown mounted to the upstream end of the frame 250, they may instead be mounted to the downstream end of the frame 250.

[0084] In other embodiments, instead of being mounted to the frame of the veneer clipper, the measuring apparatuses may be mounted to other supports, such as a frame of another device or machine (e.g., a conveyor), a wall, ceiling, structural beam, or any other suitable structure. Preferably the support(s) will be proximal to the anvil rolls. Similarly, the measuring apparatuses are preferably positioned above and below the flow path of the veneer to allow simultaneous operation of the measuring apparatuses and the veneer clipper.

[0085] The measuring apparatuses may be mounted to the support in any orientation and position that allows the measuring wheel to be moved to the resting position and to the measuring position. Typically the measuring apparatuses are oriented with the respective shafts 130 parallel to the anvil roll shafts. However, the orientation of the base 110 (if present) and/or actuator 146 relative to the anvil rolls may vary. Two possible orientations are shown by way of example in Fig. 11 B. The first measuring apparatus 100a is shown in an upright orientation with the first portion of the base 110 generally vertical and the second portion of the base generally horizontal. In this example the first portion of the base is mounted to a vertical face of the support (e.g., upper support member 264) and the actuator 146 is substantially vertical when fully extended. The second measuring apparatus 100b is shown in a tilted orientation with the first portion of base 110 and the actuator angled relative to the vertical. In this orientation, the measuring apparatus may be supported on a platform 266 that is connected to the support (e.g., lower support member 264b of frame 150). Other orientations are also possible. For example, one or both of the measuring apparatuses may be mounted in a substantially horizontal orientation. Alternatively, both measuring apparatuses may be mounted in vertical orientations or tilted orientations. Again, instead of moving the measuring wheels along an arcuate path, one or both of the measuring apparatuses may instead be configured to move the measuring wheel(s) along a linear path and may be oriented accordingly relative to the anvil rolls.

[0086] Optionally, the veneer clipper system may further include a control system. The control system may be operatively coupled with the measuring apparatuses 100a and 100b (Fig. 10). A schematic diagram of one embodiment of a control system 300 is shown by way of example in Fig. 12, and a flow chart of a method 400 for determining the diameter of an anvil roll is shown in Fig. 13.

[0087] Referring first to Fig. 13, in various embodiments, method 400 may begin at block 401 with moving a measuring wheel (e.g., measuring wheel 140) of a measuring device (e.g., measuring device 100) into contact with an anvil roll (e.g., anvil roll 52/252) of a veneer clipper. For example, at block 401 actuator 146 may be operated to move the measuring wheel from a resting position, in which the measuring wheel does not contact the anvil roll, to a measuring position in contact with the surface of the anvil roll. As the anvil roll rotates, the measuring wheel rides on the surface of the anvil roll and is driven in rotation by the anvil roll.

[0088] At block 403, feedback (e.g., measurement signals) is collected from the measuring wheel rotation sensor, and from a second rotation sensor that is operatively coupled with the anvil roll or the motor that drives the anvil roll.

Preferably, the motor is a servo motor (e.g., servo motor 254a or 254b) and the second rotation sensor is the encoder of the servo motor. Alternatively, the second rotation sensor may be mounted to the shaft of the anvil roll, or otherwise operatively coupled with the anvil roll motor or the anvil roll shaft. Optionally, feedback collection may begin after a delay, to allow the measuring wheel to stabilize against the anvil roll). Again, while the rotation sensors are typically rotary encoders, other types of sensors suitable for use to detect and indicate rotational movement can be used instead.

[0089] The feedback may be collected for a desired period of time. In some embodiments, feedback may be collected at predetermined intervals of time (e.g., at 250ms intervals) for a predetermined length of time (e.g., 10 seconds) or until a predetermined number of samples have been collected (e.g. 40 samples).

Optionally, the measuring wheel rotation sensor feedback may be sampled in a particular unit of distance per time (e.g., inches per second) and the second rotation sensor feedback may be sampled in revolutions per unit of time (e.g., revolutions per second).

[0090] Next, at block 405, the measuring wheel may be moved out of contact with the anvil roll. Preferably, this is accomplished by operating actuator 146 to move the measuring wheel from the measuring position to the resting position while the anvil roll continues to rotate.

[0091] At block 407, the diameter of the anvil roll may be calculated based on the feedback collected from the measuring wheel rotation sensor and the second rotation sensor. The feedback collected from the measuring wheel rotation sensor indicates the surface speed of the anvil roll. For example, the surface speed is equal to the rotation sensor’s resolution (travel distance of measuring wheel surface per pulse/signal output by the rotation sensor) multiplied by the number of pulses/signals output by the rotation sensor per unit of time. However, depending on the configuration of the veneer clipper system, the feedback collected from the second rotation sensor can indicate either the rotational velocity of the anvil roll or the rotational velocity of the output shaft of the motor that drives the anvil roll. For example, if the second rotation sensor is mounted to the shaft of the anvil roll, or if the anvil roll motor is connected to the anvil roll without a gear reducer and the second rotation sensor is mounted to either the shaft of the anvil roll or the output shaft of the motor, the feedback collected from the second rotation sensor would indicate the rotational speed of the anvil roll. Conversely, if the second rotation sensor is positioned to detect rotation of the motor’s output shaft and the motor’s output is transmitted to the anvil roll through a gear reducer, the feedback from the second rotation sensor would indicate the rotational velocity of the motor output shaft. [0092] If the feedback collected from the second rotation sensor indicates the rotational speed of the anvil roll, the diameter of the anvil roll may be calculated according to the formula:

Diameter = Velocity/(Speed ^* TT) where Velocity is the surface speed of the anvil roll in linear distance per unit of time (e.g., feet per minute), and Speed is the rotational speed of the anvil roll in revolutions per unit of time (e.g., RPM).

[0093] Preferably, Velocity is determined as the average of the surface speeds measured during the feedback collection period, and Speed is determined as the average of the rotational speeds measured during the feedback collection period. However, these parameters may instead be determined based on single measurements, or as the mean or median of multiple measurements, or in any other suitable manner.

[0094] The above formula may also be used to determine the anvil roll diameter if the feedback collected from the second rotation sensor indicates the rotational velocity of the motor, but the feedback is scaled or otherwise processed to indicate the rotational velocity of the anvil roll. For example, if the anvil roll motor is a servo motor, the output of the servo motor is transmitted to the anvil roll through a gear reducer, and the second rotation sensor is the encoder of the servo motor, the feedback collected from the second rotation sensor may be scaled according to the reduction value, and the scaled feedback may be used to calculate the diameter. Alternatively, instead of scaling the feedback itself, the feedback may be used to determine the rotational velocity of the motor, and that rotational velocity may be divided by the reduction value to obtain the rotational velocity of the anvil roll. For example, if the reducer ratio is 11 :1 (reduction value = 11), the rotational velocity of the motor may be divided by 11 to obtain the rotational velocity of the anvil roll. As another alternative, the diameter of the anvil roll may be calculated according to the following formula:

Diameter = (Velocity ^* Reduction)/(Speed ^* TT) where Velocity is the surface speed of the anvil roll in linear distance per unit of time, Reduction is the reduction value of the gear reducer, and Speed is the rotational speed of the anvil roll in revolutions per unit of time.

Again, Velocity and Speed may optionally be determined as averages of the surface speeds and rotational speeds measured during the feedback collection period. [0095] Optionally, at block 409 a rotational speed of the anvil roll and/or other processing equipment (e.g., a conveyor) may be controlled or adjusted based at least in part on the calculated diameter of the anvil roll. In some embodiments the rotational speed of the anvil roll may be controlled or adjusted to achieve a desired surface speed. The desired surface speed may be selected or entered by a human operator (e.g., via a user interface). Alternatively, it may be selected automatically to match a speed of an upstream conveyor or ribbon of veneer, or in some other manner. Regardless, the desired surface speed and the diameter of the anvil roll may be used to identify a target rotational speed for the respective anvil roll motor. The actual or current rotational speed of the anvil roll motor may then be adjusted (increased or decreased) to match the determined target rotational speed.

[0096] For example, if the rotational speed of the motor is equal to the rotational speed of the anvil roll, the target rotational speed for the motor may be determined according to the following formula:

Target = Desired surface speed/(anvil roll diameter ^* TT)

[0097] If the rotational speeds of the motor and anvil roll are different, as when the anvil roll motor transmits power to the anvil roll through a gear reducer, the target rotational speed may be determined according to the following formula:

Target = (Desired surface speed ^* Reduction Value)/(anvil roll diameter ^* TT)

[0098] For instance, in a veneer clipper system with an anvil roll that is driven by a motor via a gear reducer with a gear ratio of 11 :1 , with a desired surface speed of 600 feet/minute, when the anvil roll has a diameter of 11 inches the target rotational speed for the motor would be 2293 RPM. If the diameter of the anvil roll deceases to 10 inches, the target rotational speed for the motor would increase to 2522.3 RPM. The operation of the motor would be adjusted by increasing the rotational speed of the motor to the target rotational speed to maintain the desired surface speed of the anvil roll.

[0099] Optionally, at block 411 , the calculated diameter of the anvil roll may be displayed (e.g., on a computer monitor, touchscreen, or other electronic visual display).

[00100] Optionally, at block 413, one or more additional parameters may be determined based at least in part on the calculated diameter of the anvil roll. For example, in some embodiments an estimated amount of wear, and/or an estimated remaining service life, may be determined based at least in part on the calculated diameter. The estimated remaining service life may be determined based on the calculated diameter, a maximum diameter of the anvil roll, and a minimum diameter for the anvil roll. The maximum diameter may be an ideal diameter or initial diameter of the anvil roll, such as the diameter of the roll prior to its first use. The minimum diameter may be a diameter at which most or all of the coating on the anvil roll has been removed, and/or a predetermined diameter at which the anvil roll is intended to be replaced or recoated. One example of a suitable formula for calculating an estimated remaining service life is:

L = ((Diametercurrent - DiameterMin)/(DiameterMax - DiameterMin)) ^* 100 where Diametercu _rrent is the anvil roll diameter calculated at block 407, Diameter _Min is a minimum diameter for the anvil roll (e.g., the diameter at which the anvil roll should be replaced), and Diametenvi _ax is an initial or ideal diameter for the anvil roll (e.g., the diameter of the anvil roll prior to any wearing or removal of the coating).

[00101] In a typical veneer clipper system, the maximum diameter of the anvil roll is 11 inches and the minimum diameter of the anvil roll is 9 inches. However, the maximum and minimum diameters may vary among embodiments.

[00102] Optionally, at block 415 the additional parameter(s) may be displayed. [00103] Some of the operations of method 400 may be performed simultaneously. For example, blocks 413 and 415 may be performed at the same time as block 409 or block 411. In addition, in some embodiments of the method, any one or more (or all) of blocks 411 , 413, and 415 may be omitted.

[00104] In various embodiments, some or all of the operations of method 400 may be performed by a control system. An embodiment of a suitable control system is illustrated by way of example in Fig. 12.

[00105] Referring now to that Figure, control system 300 may include a controller 300b. Optionally, control system 300 may further include an operator interface 300a and/or a servo drive 300c.

[00106] Operator interface 300a is hardware, software, or a combination of hardware and software, configured to provide a user interface for use by a human operator to interact with controller 300b. In some embodiments, operator interface 300a includes a computing device programmed to render user interface controls in a graphical user interface (GUI) for controlling various operations of a veneer clipper system (e.g., veneer clipper system 200). An example of a suitable graphical user interface (GUI) 600 is illustrated in Fig. 15 and described further below. Operator interface 300a may be, or may include, one or more of a personal computer (PC), tablet, laptop, smart phone, server, or other computing device that includes a processor and a memory. Operator interface 300a may be configured to receive input from, and to provide output to, a human operator through various input/output devices (e.g., keyboard, mouse, display, touchscreen, joystick, touchpad, etc.). [00107] Controller 300b may be a programmable controller. Typically, controller 300b is a programmable logic controller (PLC). However, controller 300b may instead be a programmable automation controller, a programmable motion controller or other type of programmable controller, a PC, or other suitable computing device. Controller 300b and operator interface 300a may be separate devices, or they may be integrated in one device (e.g., a PC or PLC) that performs the functions of both. For example, in some embodiments controller 300b may be a PLC or an industrial PC and operator interface 300a may be an integrated display or touchscreen.

[00108] Regardless, controller 300b is configured to control the measuring wheel actuators 146a and 146b. Controller 300b may control the actuators by sending control signals to the actuators. Alternatively, controller 300b may control the actuators by sending control signals to an intermediate device 300d, which may be a switch, a valve, or other such device that is operatively coupled to the actuator. Preferably, controller 300b is also configured to send control signals to, and to receive measurement data from, a servo drive 300c. Servo drive 300c is configured to receive feedback signals from rotation sensors 142a, 142b, 268a, and 268b, and to send control signals to motors 154a and 154b in some embodiments. In other embodiments, servo drive 300c may be configured to receive feedback signals from encoders 268a and 268b, and controller 300b may receive feedback signals directly from encoders 142a and 142b, or from another servo drive (not shown) that receives the feedback signals from encoders 142a and 142b and sends corresponding measurement data to controller 300b. Optionally, the servo drive(s) may scale the received feedback as discussed above.

[00109] Fig. 14 is a flow chart of a process for determining the diameter of an anvil roll, in accordance with various embodiments. The process may be performed by a control system, such as control system 300. [00110] The process begins at block 501 . At this stage, the measuring wheel is in the resting or retracted position.

[00111] At block 503, controller 300b determines whether the measuring sequence has been initiated. In some embodiments, the measuring sequence may be initiated by user input entered by a human operator. In that case, the user input may be entered by selecting a virtual button or other selectable element (e.g., in the GUI 600), or entering a command with a mouse, keyboard, or other input device, and the operator interface 300a may send a command signal to the controller 300b in response to receiving the user input. Alternatively, the operator interface 300a may be programmed to send the command signal to the controller 300b automatically at selected times or intervals of time, or after a selected number of knife clips, or the like. As another alternative, the controller 300b may be programmed to initiate the measuring sequence automatically (without receiving a command signal from the operator interface) at selected times or intervals of time, or after a selected number of knife clips, etc. The times, intervals, number of knife clips, or other parameter(s) for automatic initiation of the sequence may optionally be selected or entered by a human operator via the GUI.

[00112] If the controller 300b determines at block 503 that the measuring sequence has not been initiated, the process may return to the start (block 501). [00113] In response to determining that the measuring sequence has been initiated, the controller 300b causes the actuator 146 to move the measuring wheel into contact with the respective anvil roll (i.e. , to the measuring position). Controller 300b may accomplish this in various ways, depending on the type of actuator. In some embodiments, controller 300b may control the actuator 146 by controlling an intermediate device 300d, which may be a switch, a valve, or other such device that is operatively coupled to the actuator. For example, if actuator 146 is a pneumatic or hydraulic cylinder, the controller 300b may operate the cylinder by sending control signals to a control valve that regulates the flow of fluid to and from the cylinder. The control valve may be a solenoid valve, a motor valve, or any other suitable type of valve. As another example, if actuator 146 is an electro-mechanical actuator with an electric motor, controller 300b may control the actuator by sending control signals to the electric motor, either directly or indirectly (e.g., through a servo drive or other control device). In a particular embodiment, actuator 146 is a double-acting pneumatic cylinder connected to an air supply via a solenoid-controlled valve. If present, intermediate device 300d may be operatively coupled to (and used to control) the actuators of both measuring devices, or each of the actuators 146 may be controlled by a respective intermediate device 300d. In other embodiments, controller 300b may control the actuator(s) 146 by sending control signals directly to the actuator(s).

[00114] At block 507, the controller 300b receives measurement data. Optionally, the controller 300b may begin to collect measurement data after a delay period in order to allow the measuring wheel to stabilize against the surface of the anvil roll, or may disregard measurement data received within the delay period. In some embodiments, servo drive 300c receives feedback signals from the measuring wheel rotation sensors (142a and/or 142b) and the corresponding second rotation sensors (268a and/or 268b) and processes the received signals to generate the measurement data, and the controller 300b receives the measurement data from servo drive 300. Optionally, servo drive 300c may be configured to scale the received feedback signals to provide the measurement data in a selected unit of measurement and/or to convert measurements of one component (e.g., revolutions of the motor output shaft) to measurements of another component (e.g., revolutions of the anvil roll). For example, in embodiments with a gear reducer, the servo drive 300c may be configured to scale the feedback signals received from the second rotation sensor based on the reduction ratio of the gear reducer. Other embodiments may lack servo drive 300c, and the controller 300b may receive measurement data directly from the measuring wheel rotation sensor (142a and/or 142b) and the corresponding second rotation sensor (268a and/or 268b), or from another type of drive operatively coupled with the encoders.

[00115] At block 509, the controller 300b determines whether the measuring sequence is completed. In some embodiments, the controller is programmed to receive measurement data in the form of measurements and to determine that the measuring sequence is complete in response to receiving a predetermined number of the measurements. Again, in some embodiments, feedback may be collected at predetermined intervals of time (e.g., at 250ms intervals) for a predetermined length of time (e.g., 10 seconds) or until a predetermined number of samples have been collected (e.g. 40 samples). Optionally, the measuring wheel rotation sensor feedback may be sampled in a particular unit of distance per time (e.g., inches per second) and the second rotation sensor feedback may be sampled in revolutions per unit of time (e.g., revolutions per second). In other embodiments, the controller is programmed to receive measurement data for a predetermined length of time, or until it receives a command from the operator interface 300a to end the measurement sequence.

[00116] In response to determining that the measurement is completed, the controller 300b operates the actuator to move the measuring wheel away from contact with the anvil roll (e.g., to the resting or retracted position) at block 513. Again, the controller 300b may operate the actuator by sending a signal to an intermediate device 300d operatively coupled with the actuator(s), such as a corresponding valve, motor, or the like.

[00117] At block 515, the controller 300b calculates the diameter of the anvil roll based on the measurement data received during the measuring sequence. The controller may calculate the diameter of the anvil roll in the manner described above with reference to block 407.

[00118] At block 517, the controller 300b may optionally send the calculated diameter to the operator interface 300a.

[00119] Optionally, at block 519 the controller 300b may determine one or more additional parameters (e.g., estimated remaining service life of the anvil roll) in the manner described above with regard to block 413. At block 521 , the controller 300b may send the determined additional parameter(s) to the operator interface 300a.

[00120] After calculating the diameter of the anvil roll, the controller 300b may adjust or control the corresponding anvil roll motor based on the calculated diameter, as described above with regard to block 409.

[00121] In other embodiments, operator interface 300a may perform any or all of the operations of blocks 515, 517, 519, and 521. For example, at block 507 controller 300b may send the received measurement data to operator interface 300a and operator interface 300a may determine, and display and/or transmit, the diameter of the anvil roll and/or the additional parameter(s). Alternatively, controller 300b may determine the diameter of the of the anvil roll and transmit the determined diameter to operator interface 300a, and operator interface 300a may determine and display/transmit the additional parameter(s).

[00122] Optionally, in some embodiments, the control system may track the measured diameters of the anvil rolls over time and use that information to detect wearing trends, provide a recommendation to the operator, and/or estimate a predicted duration of use for the anvil rolls. For example, the control system may determine that the diameter of the upper anvil roll is decreasing more rapidly than the diameter of the lower anvil roll, or vice versa, and generate a maintenance recommendation based on the determination (e.g., a recommendation to adjust the position of the affected anvil roll or the knife). As another example, the control system may calculate a rate of wear for the anvil roll based on the reduction in measured diameter from one measurement period to the next, determine an estimated end of service life date based on the rate of wear, and generate a recommended replacement date for the anvil roll.

[00123] In various embodiments, operator interface 300a may be configured to display the calculated diameters and optionally other parameters in a user interface, such as a GUI. Figure 15 illustrates an example of a graphical user interface 600, in accordance with various embodiments.

[00124] In the illustrated embodiment, user interface 600 includes a measurement sequence window 601 that indicates the current diameter of the anvil rolls, as measured in the most recent measurement sequence. The measurement sequence window 601 includes fields that indicate the current diameter of the top anvil roll (field 603) and the bottom anvil roll (605). Optionally, the measurement sequence window 601 also includes fields that indicate the diameters of the top anvil roll (field 607) and the bottom anvil roll (field 609) as measured in the next-most- recent measurement sequence (‘last diameter’). The measurement sequence window 601 may also display other information, such as the relevant unit(s) of measure.

[00125] Optionally, measurement sequence window 601 includes a status field 613 that indicates the status of the measurement sequence. For example, referring again to the method illustrated in Fig. 14, at block 501 (e.g., between measurement sequences), status field 613 may indicate a state of readiness for a new measurement sequence (e.g., “Encoder Speed Check Ready”). At block 505, status field 613 may indicate that the measuring wheels are being moved to the measuring position (e.g., “Extending Measuring Wheels” or “Lower Encoders”, etc.). Again, while this example refers to encoders, other types of rotation sensors may be substituted for encoders. At block 507, status field 613 may indicate that the control system is collecting measurements from the motor rotation sensors and the measuring wheel rotation sensors (e.g., “Measure Speeds and RPMs”). At block 513, status field 613 may indicated that the measuring wheels are being moved from the measuring position to the retracted or resting position (e.g., “Retracting Measuring Wheels” or “Raise Encoders”). At block 515 and/or block 517, status field 613 may indicate that the current diameter values are being updated (e.g., “Adjust Diameter of Rolls”). Fields 607 and 609 may be updated to display the previous ‘current diameter’ values for the respective anvil rolls, and fields 603 and 605 may be updated to display the new ‘current diameter’ values for the respective anvil rolls. [00126] In some embodiments, user interface 600 may have a user control 611 , such as a virtual button or the like, that is selectable or otherwise operable by the user to initiate a new measurement sequence. Alternatively, in embodiments in which the measurement sequence is initiated automatically by the control system, user control 611 may optionally be omitted.

[00127] User interface 600 may also include a rotation speed window 615 with fields 617 and 619 that indicate the rotational speeds of the top and bottom anvil rolls as measured by the respective rotation sensors (e.g., second rotation sensor 268a and 268b). Preferably, fields 617 and 619 are continuously updated during the measurement sequence to display each measured rotational speed of the anvil rolls substantially in real time. In addition, user interface 600 may include a manual measuring device control window 621 . This window may include a user control 623 and a status field 625. The user control 623 may be selectable by the user to move the measuring wheels from the retracted/resting position to the measuring position (e.g., for testing or maintenance purposes). The status field 627 may indicate the position of the measuring wheels (e.g., “Lowered” or “Reset”). Again, any or all of rotation speed window 615, manual measuring device control window 621 , and fields 617, 619, 621 , and 623 may optionally be omitted.

[00128] User interface 600 may optionally include a clipper line speed window 627 with a field 629 for entering or displaying an actual or desired speed of the clipper line. Preferably, field 629 displays a desired clipper line speed that is entered or selected by the user, and the control system controls the rotational speed of the anvil rolls based on the current diameters of the anvil rolls and the desired clipper line speed.

[00129] In some embodiments, user interface 600 includes additional fields that indicate the degree of wearing or the estimated remaining service life of the anvil rolls. For example, in the illustrated embodiment, the current diameters of the top and bottom anvil rolls are displayed in fields 631 and 635, respectively, and the estimated remaining service life of the top and bottom anvil rolls are displayed in fields 633 and 637, respectively. Referring again to Fig. 14, these fields may be updated at block 517 and/or block 521 .

[00130] User interface 600 may optionally include other fields, controls, and/or other features for receiving user input, displaying the status of various clipper components, and the like. For example, user interface 600 may have fields and user controls for setting knife positions, displaying clip response time and cycle time, and/or other parameters.

[00131] Embodiments of controller 300b and operator interface 300a are shown in Figs. 16 and 17, respectively.

[00132] Referring first to Fig. 16, controller 300b may include a processor 702 and a memory 704 in communication with the processor 702. Optionally, memory 704 and processor 702 may be integrated in a central processing unit (CPU) 708. Controller 300b may also include one or more input modules 712 (e.g., input cards) and one or more output modules 714 (e.g., output cards), and one or more communications interfaces 710. Optionally, controller 300b may also include a power supply 716 configured to convert AC power to DC power. Memory 704 may include volatile memory, non-volatile memory, or both. In some embodiments, memory 704 includes a Random Access Memory (RAM). Optionally, memory 704 may also include Read Only Memory (ROM), firmware, flash memory, a hard disk drive, a solid-state drive, an external storage resource/device, and/or any other suitable type of memory.

[00133] Memory 704 includes logic 706 and data 718. Logic 706 includes instructions that are executable by the processor 702 to perform the operations of controller 300b as described herein, such as operating the measuring wheel actuator(s) (e.g., actuator(s) 146), receiving feedback data from the servo drive 300c, and determining the diameter(s) of the anvil roll(s) and/or additional parameters based on the received feedback data. For example, in some embodiments the instructions may be executable by the processor 702 to perform some or all of the steps of method 400 (e.g., blocks 401-407 and optionally block 409 and/or 413) and/or the operations of blocks 503-517 (and optionally 519 and/or 521). [00134] In operation, feedback data from the servo drive 300c is sent through input module(s) 712 to processor 702, which processes the feedback data according to logic 706. Processor 702 updates the determined roll diameter values and/or other information (e.g., status of inputs and outputs, additional parameters, etc.) in memory 704. Command signals from processor 702 are sent through output module(s) 714 to the servo drive 300c and to the measuring wheel actuator(s) 146 and/or intermediate device(s) 300d. Processor 702 sends the determined anvil roll diameters and optionally other information (e.g., measurement data, current status of motors/actuators, current status of measurement sequence, etc.) to operator interface 300a, and receives data from operator interface 300a, through communications interface(s) 710.

[00135] Referring now to Fig. 17, operator interface 300a may include a computer system. The computer system may include a computing device, such as a tablet, touch screen PC, laptop computer, desktop computer, or a server computer). The computing device typically includes system control logic 802 coupled to one or more processor(s) 804 (e.g., a processor core), memory 806/808 coupled to system control logic 806, and one or more communications interface(s) 810 coupled to system control logic 802. Operator interface 300a may also include an interface device 816, such as a display screen or touchscreen, configured to display the user interface. Optionally, operator interface 300a may further include one or more additional input/output (I/O) devices 818 (e.g., a keyboard, mouse, camera, projector, speaker, or a manually operated button, pedal, joystick, or switch, etc.) configured to receive input from, or present data to, a human operator. System control logic 802 may include any suitable interface controller(s) to provide for any suitable interface to at least one of the processor(s) 804 and/or any suitable device or component in communication with system control logic 802. System control logic 802 may also interoperate with input/output device 816 and/or input/output device(s) 818.

[00136] System control logic 802 may include one or more memory controller(s) to provide an interface to memory 806. Memory 806 may be used to load and store data and/or instructions. Memory 806 may include any suitable volatile memory, such as RAM and/or dynamic random access memory (“DRAM”). NVM/storage 808 may be used to store data and/or instructions. NVM/storage 808 may include any suitable non-volatile memory, such as flash memory, and/or any suitable non-volatile storage device(s), such as one or more hard disk drive(s) (“HDD(s)”), one or more solid-state drive(s), one or more compact disc (“CD”) drive(s), and/or one or more digital versatile disc (“DVD”) drive(s). In some embodiments, system control logic 802 may include one or more input/output (“I/O”) controller(s) to provide an interface to NVM/storage 808 and communications interface(s) 810.

[00137] In some embodiments, system memory 806, NVM/storage 808, and/or system control logic 802 may include program logic 812 and/or data 814. Program logic 812 includes instructions that are executable by the processor(s) 804 to perform some or all of the operations of operator interface 300a described herein, such as rendering/displaying a user interface (e.g., GUI 600) for a rotary clipper system or component(s) thereof, processing operator input (e.g., instructions, operational parameters, set-points, etc.), sending command signals to controller 300b, processing data received from controller 300b, and updating the user interface and/or memory.

[00138] Communications interface(s) 810 may provide an interface for the operator interface 300a to communicate over one or more network(s) and/or with other devices (e.g., controller 300b, server(s), etc.). Communications interface(s)

810 may include any suitable hardware and/or firmware, such as a network adapter, one or more antennas, a wireless interface, and so forth.

[00139] Optionally, NVM/storage 808 may include a storage resource that is accessed over a network via the communications interface(s) 810. Similarly, in some embodiments the computer system includes two or more computer devices and the functions/operations of operator interface 300a are distributed among the computer devices. As an example, the computer system may include one or more servers that perform some or all of the data processing and/or data storage, and a client computer that interacts with the server(s) and presents the user interface on the interface device 816. Optionally, operator interface 300a may be an industrial HMI operator station with an integrated touchscreen.

[00140] Measuring apparatuses and/or control systems as disclosed herein may be provided as modifications or upgrades to existing rotary veneer clippers. In various embodiments, a method of modifying or upgrading a rotary veneer clipper includes operatively coupling a measuring apparatus 100 with the rotary veneer clipper, such that the actuator 146 is selectively actuable to move the shaft 130 and/or measuring wheel 142 along the path of travel (e.g., 112) into and/or away from contact with an anvil roll of the rotary veneer clipper. Operatively coupling the measuring apparatus with the rotary veneer clipper may include mounting the actuator 146 and/or base 110 (if present) to the frame of the rotary veneer clipper or to another support structure in an operating position. In some embodiments the anvil roll may be driven by a servo motor and the method may further include operatively coupling the servo motor and the measuring apparatus (e.g., actuator 146) with a control system, such as control system 300. Optionally, the method may further include operatively coupling the anvil roll with the servo motor (e.g., if the existing rotary veneer clipper included a different type of motor to drive the anvil roll).

Examples

[00141] The present disclosure describes methods, apparatuses, and systems for measuring the diameter of a roll, such as the anvil roll of a veneer clipper. The anvil roll has opposite ends, a first rotational axis that extends through the ends, and an outer surface that defines the diameter of the anvil roll.

[00142] In some embodiments a measuring device may be used to measure the diameter of the anvil roll. The measuring device includes a measuring wheel, a first rotation sensor operatively coupled with the measuring wheel, and an actuator coupled with the measuring wheel and mounted to a support.

[00143] In some embodiments, a method of using the measuring device to measure the diameter of the anvil roll includes moving the measuring wheel from a retracted position, in which the measuring wheel is not in contact with the anvil roll, to a measuring position, in which the measuring wheel is in contact with the anvil roll, while the anvil roll rotates about the first rotational axis, collecting feedback from the first rotation sensor while the measuring wheel is in the measuring position and is being driven in rotation by the anvil roll, moving the measuring wheel from the measuring position to the retracted position after collecting the feedback, and determining a diameter of the anvil roll based at least on the feedback from the first rotation sensor. In some embodiments, moving the measuring wheel includes operating the actuator to move the measuring wheel to one or both of said positions. [00144] In some embodiments the anvil roll is coupled with a second rotation sensor that is operable to detect rotation of the anvil roll, and the method further includes collecting feedback from the second rotation sensor while collecting feedback from the first rotation sensor, and determining the diameter of the anvil roll based in part on the feedback from the second rotation sensor.

[00145] In some embodiments the anvil roll is driven by a motor operatively coupled with the anvil roll, a second rotation sensor is operable to detect rotation of an output shaft of the motor, and the method further includes collecting feedback from the second rotation sensor. In such embodiments, determining the diameter of the anvil roll may include determining a surface speed of the anvil roll based on the feedback from the first rotation sensor, determining a rotational speed of the anvil roll or the output shaft of the motor based at least in part on the feedback from the second rotation sensor, and determining the diameter of the anvil roll based on the determined rotational speed and the determined surface speed.

[00146] In some embodiments the motor may be operatively coupled with a gear reducer, and the rotational speed of the anvil roll may be determined based on the feedback from the second rotation sensor and a reduction value of the gear reducer. For example, the reduction value of the gear reducer may be 11”, and the anvil roll may have a maximum diameter of 11”. In some embodiments the motor is a servo motor, and the servo motor includes the second rotation sensor (e.g., a rotary encoder).

[00147] In some embodiments the method further includes determining an amount of wear or an estimated remaining service life of the anvil roll based on the determined diameter of the anvil roll, a maximum diameter of the anvil roll, and a minimum diameter of the anvil roll, wherein the maximum diameter is an ideal or initial diameter of the anvil roll prior to use and the minimum diameter is a diameter at which the anvil roll is to be replaced or recoated.

[00148] In some embodiments the method further includes adjusting a rotational speed of the anvil roll based at least in part on the determined diameter of the anvil roll.

[00149] In various embodiments, an apparatus/system for measuring the diameter of an anvil roll of a rotary veneer clipper while the anvil roll is in rotation about a first rotational axis, wherein the anvil roll has an outer surface, opposite ends, and the first rotational axis extends through the ends, includes a base configured to be fixedly mounted to a support, an actuator coupled to the base, a shaft rotatably coupled with the actuator, a measuring wheel coupled to the shaft such that the shaft is driven in rotation by rotation of the measuring wheel, and a rotation sensor coupled with the shaft and operable to detect rotation of the shaft.

The actuator is selectively actuable to move the shaft relative to the base to thereby move the measuring wheel along a path of travel between a retracted position and an extended position.

[00150] In some embodiments the apparatus/system further includes a support arm coupled with the base and the actuator, the shaft is rotatably mounted to the support arm, and the rotation sensor is mounted to the support arm.

[00151] In some embodiments the actuator is a linear actuator.

[00152] In some embodiments the base has a first portion and a second portion that meet at an angle, a first end of the actuator is pivotably connected to the first portion of the base, a first end of the support arm is pivotably connected to the second portion of the base, and a second end of the support arm is pivotably connected to a second end of the actuator, and the path of travel is an arcuate path of travel.

[00153] In some embodiments a first end of the actuator is mounted to the base and the shaft is rotatably connected to an opposite second end of the actuator, and the actuator is selectively actuable to move the measuring wheel along a linear path of motion.

[00154] A rotary veneer clipper may include at least one anvil roll, a motor operatively coupled with the anvil roll, and a measuring device that includes a measuring wheel, a means for moving the measuring wheel into and/or away from contact with the anvil roll, and a first rotation sensor positioned to detect rotation of the measuring wheel. In various embodiments, a control system for the rotary veneer clipper is configured to control the means for moving the measuring wheel and/or to determine a current diameter of the anvil roll based on a surface speed of the anvil roll and a rotational speed of the motor or the anvil roll, wherein the surface speed and the rotational speed are measured based on feedback collected from the first rotation sensor and the motor, respectively, while the measuring wheel is driven in rotation by the anvil roll. The control system may be configured to adjust operation of the motor based at least on the current diameter and/or cause an interface device (e.g., a display screen or a touchscreen) to display the current diameter.

[00155] In some embodiments the measuring device further includes an actuator that is operable to move the measuring wheel to a measuring position, in which the measuring wheel is in contact with the anvil roll, and/or a retracted position, in which the measuring wheel is out of contact with the anvil roll, and wherein the control system is configured to operate the actuator to move the measuring wheel to one of said positions.

[00156] In some embodiments the motor is a servo motor with a second rotation sensor, and the control system is configured to receive the feedback from the rotation sensors, determine the surface speed of the anvil roll based on the feedback from the first rotation sensor, and determine the rotational speed based on the feedback from the second rotation sensor.

[00157] In some embodiments the control system includes a servo drive in communication with the rotation sensors and the motor, and a computer or programmable controller in communication with the servo drive and the operator interface. The measuring device may further include an actuator that is operable to move the measuring wheel to a measuring position, in which the measuring wheel is in contact with the anvil roll, and/or a retracted position, in which the measuring wheel is out of contact with the anvil roll, and the computer or programmable controller may be configured to operate the actuator to move the measuring wheel to one of said positions.

[00158] In some embodiments the control system is configured to estimate an amount of wear or remaining service life of the anvil roll based on the current diameter, a minimum diameter of the anvil roll, and a maximum diameter of the anvil roll, and to cause the operator interface to display the estimated amount of wear or remaining service life of the anvil roll.

[00159] In various embodiments, a rotary veneer clipper includes a frame, a first anvil roll rotatably coupled to the frame, and a measuring device as described herein. The first measuring apparatus is mounted to the frame, or to a support, in an operating position such that the actuator is selectively actuable to move the measuring wheel along the path of travel into and/or away from contact with the first anvil roll while the first anvil roll is in rotation.

[00160] In some embodiments the rotary veneer clipper further includes a second anvil roll rotatably coupled to the frame above or below, and parallel to, the first anvil roll; and a second measuring device as described herein. The second measuring device is mounted to the frame, or to the support or other structure, in a respective operating position relative to the second anvil roll, such that the actuator of the second measuring apparatus is operable to move the measuring wheel of the second measuring apparatus into and/or away from contact with the second anvil roll while the second anvil roll is in rotation. Optionally, the rotary veneer clipper may further include a controller configured to automatically control the actuator of the first measuring apparatus in response to initiation of a measuring sequence.

[00161] Although certain embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope. Those with skill in the art will readily appreciate that embodiments may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments be limited only by the claims and the equivalents thereof.