Abstract: A compression molding system includes a first extruder to output melted plastic, and a second extruder downstream from the first extruder to mix the melted plastic with wood chips to output a composite material. A transfer valve alternately directs the composite material between inner block molds and outer block molds. Each inner block mold has an inner block press associated therewith to press the composite material into a desired shape of an inner block having an opening on one side. Each outer block mold has an outer block press associated therewith to press the composite material into a desired shape of an outer block having an opening on one side. A press assembly presses one of the inner blocks into the opening in one of the outer blocks to form a double wall block.

Abstract: A nail plater apparatus includes at least one nail plate magazine configured to hold a plurality of nail plates, and at least one nail plate extractor assembly associated with the at least one nail plate magazine and configured to position at least one nail plate therefrom to at least one nail plate pressing area. A board feeder is configured to position a board to a board receiving area. At least one nail plate presser assembly is adjacent the board receiving area and aligned with the at least one nail plate pressing area and configured to press the at least one nail plate into the board.

Abstract: A pallet positioning station for positioning a pallet to be impacted by a pallet impact station includes a pallet push arm assembly adjacent the pallet impact station. The pallet push arm assembly includes a pallet push arm movable between a retracted position and a pallet positioning position. A controller is configured to move the pallet push arm to the retracted positions to receive the pallet for positioning, and move the pallet push arm to the pallet positioning position to position the pallet towards the pallet impact station for impact.

Abstract: A method for operating a pallet positioning station for positioning a pallet to be impacted by a pallet impact station is provided. The pallet positioning station includes a pallet push arm assembly adjacent the pallet impact station. The pallet push arm assembly includes a pallet push arm movable between a retracted position and a pallet positioning position. The method includes moving the pallet push arm to the retracted position to receive the pallet for positioning, and moving the pallet push arm to the pallet positioning position to position the pallet towards the pallet impact station for impact.

Abstract: A pallet impact station includes a frame, at least one pendulum swing arm rotatably coupled to the frame, a carriage assembly carried by the at least one pendulum swing arm for impacting a pallet, and a latching mechanism extending between the frame and the at least one pendulum swing arm. The latching mechanism disengages the at least one pendulum swing arm at a raised position so that the carriage assembly impacts the pallet. A controller operates the latching mechanism to disengage the at least one pendulum swing arm.

Abstract: A method for operating a pallet positioning station for positioning a pallet to be impacted by a pallet impact station is provided. The pallet positioning station includes a frame adjacent the pallet impact station, a pallet lift assembly carried by the frame that includes a lift grate moveable between a retracted position and an extended position, and a pallet push arm assembly carried by the frame that includes a pallet push arm movable between a retracted position and a pallet positioning position. The method includes moving the pallet push arm and the lift grate to the retracted positions to receive the pallet for positioning, moving the lift grate to the extended position when the pallet is to be positioned for impact by the pallet impact station, and moving the pallet push arm to the pallet positioning position to position the pallet towards the pallet impact station until the pallet is aligned with an impact reference plane.

Abstract: A pallet positioning station for positioning a pallet to be impacted by a pallet impact station includes a frame, and a pallet lift assembly carried by the frame. The pallet lift assembly includes a lift grate moveable between a retracted position and an extended position. A pallet push arm assembly is carried by the frame and includes a pallet push arm movable between a retracted position and a pallet positioning position. A controller is configured to move the pallet push arm and the lift grate to the retracted positions to receive the pallet for positioning, and move the lift grate to the extended position when the pallet is to be positioned for impact by the pallet impact station. The controller is further configured to move the pallet push arm to the pallet positioning position to move the pallet towards the pallet impact station until the pallet is aligned with an impact reference plane.

Abstract: A nail plater apparatus includes at least one nail plate magazine configured to hold a plurality of nail plates, and at least one nail plate extractor assembly associated with the at least one nail plate magazine and configured to position at least one nail plate therefrom to at least one nail plate pressing area. A board feeder is configured to position a board to a board receiving area. At least one nail plate presser assembly is adjacent the board receiving area and aligned with the at least one nail plate pressing area and configured to press the at least one nail plate into the board.

Abstract: A pallet impact station includes a frame, at least one pendulum swing arm rotatably coupled to the frame, a carriage assembly carried by the at least one pendulum swing arm for impacting a pallet, and a latching mechanism extending between the frame and the at least one pendulum swing arm. The latching mechanism disengages the at least one pendulum swing arm at a raised position so that the carriage assembly impacts the pallet. A controller operates the latching mechanism to disengage the at least one pendulum swing arm.

Abstract: A nail plater apparatus includes a board magazine configured to hold stacked boards, and a pair of spaced apart nail plate magazines, with each nail plate magazine configured to hold stacked nail plates. The nail plater apparatus includes a pair of spaced apart nail plate extractor assemblies, with each nail plate extractor assembly associated with a respective nail plate magazine and configured to position a nail plate therefrom to a respective nail plate pressing area. A board feeder is configured to position a board from the board magazine to a board receiving area, with ends of the board being aligned with the nail plates positioned in the respective nail plate pressing areas. A pair of spaced apart nail plate presser assemblies overlie ends of the board receiving area and is aligned with the respective nail plate pressing areas to press the nail plates into the ends of the board.

Abstract: A pallet tester includes a pallet positioning station for positioning a pallet on a conveyor, and a pallet impact station adjacent the conveyor and aligned with the pallet positioning station. The pallet positioning station includes a pallet push arm movable between a retracted position and a pallet positioning position. The pallet impact station includes a carriage assembly to impact the pallet, and a latching mechanism coupled to the carriage assembly. A controller moves the pallet push arm to the retracted position to receive the pallet for positioning, and moves the pallet push arm to the pallet positioning position to move the pallet towards the pallet impact station until an impact side of the pallet is aligned with an impact reference plane.

Abstract: A pallet impact station includes a frame, at least one pendulum swing arm rotatably coupled to the frame, and a carriage assembly carried by the at least one pendulum swing arm. A latching mechanism extends between the frame and the at least one pendulum swing arm, and engages the at least one pendulum swing arm when the carriage assembly is in a lowered position, raises the carriage assembly to a raised positon, and disengages the at least one pendulum swing arm at the raised positon so that the carriage assembly strikes a pallet. A sensor generates a signal corresponding to how high the carriage assembly is raised. A controller operates the latching mechanism, including disengaging the at least one pendulum swing arm when a height of the carriage assembly corresponds to a desired release height so that a predetermined impact force strikes the pallet.

Abstract: A pallet positioning station for positioning a pallet to be impacted by a pallet impact station includes a frame, and a pallet lift assembly carried by the frame. The pallet lift assembly includes a lift grate moveable between a retracted position and an extended position. A pallet push arm assembly is carried by the frame and includes a pallet push arm movable between a retracted position and a pallet positioning position. A controller is configured to move the pallet push arm and the lift grate to the retracted positions to receive the pallet for positioning, and move the lift grate to the extended position when the pallet is to be positioned for impact by the pallet impact station. The controller is further configured to move the pallet push arm to the pallet positioning position to move the pallet towards the pallet impact station until the pallet is aligned with an impact reference plane.

Abstract: A method for operating a pallet positioning station for positioning a pallet to be impacted by a pallet impact station is provided. The pallet positioning station includes a frame adjacent the pallet impact station, a pallet lift assembly carried by the frame that includes a lift grate moveable between a retracted position and an extended position, and a pallet push arm assembly carried by the frame that includes a pallet push arm movable between a retracted position and a pallet positioning position. The method includes moving the pallet push arm and the lift grate to the retracted positions to receive the pallet for positioning, moving the lift grate to the extended position when the pallet is to be positioned for impact by the pallet impact station, and moving the pallet push arm to the pallet positioning position to position the pallet towards the pallet impact station until the pallet is aligned with an impact reference plane.

Abstract: A pallet positioning station for positioning a pallet on a roller conveyor to be impacted by a pallet impact station includes a frame adjacent the roller conveyor, and a pallet lift assembly carried by the frame and positioned below the roller conveyor. The pallet lift assembly includes a lift grate moveable between a retracted position and an extended position. A pallet push arm assembly is carried by the frame and includes a pallet push arm movable between a retracted position and a pallet positioning position. A controller is configured to move the pallet push arm and the lift grate to the retracted positions to receive the pallet for positioning, and move the lift grate to the extended position when the pallet is to be positioned for impact by the pallet impact station, with the pallet being lifted off of the roller conveyor by the lift grate.

Abstract: A pallet tester includes a pallet positioning station for positioning a pallet on a conveyor, and a pallet impact station adjacent the conveyor and aligned with the pallet positioning station. The pallet positioning station includes a pallet push arm movable between a retracted position and a pallet positioning position. The pallet impact station includes a carriage assembly to impact the pallet, and a latching mechanism coupled to the carriage assembly. A controller moves the pallet push arm to the retracted position to receive the pallet for positioning, and moves the pallet push arm to the pallet positioning position to move the pallet towards the pallet impact station until an impact side of the pallet is aligned with an impact reference plane.

Abstract: A pallet positioning station for positioning a pallet on a roller conveyor to be impacted by a pallet impact station includes a frame adjacent the roller conveyor, and a pallet lift assembly carried by the frame and positioned below the roller conveyor. The pallet lift assembly includes a lift grate moveable between a retracted position and an extended position. A pallet push arm assembly is carried by the frame and includes a pallet push arm movable between a retracted position and a pallet positioning position. A controller is configured to move the pallet push arm and the lift grate to the retracted positions to receive the pallet for positioning, and move the lift grate to the extended position when the pallet is to be positioned for impact by the pallet impact station, with the pallet being lifted off of the roller conveyor by the lift grate.

Abstract: A pallet impact station includes a frame, at least one pendulum swing arm rotatably coupled to the frame, and a carriage assembly carried by the at least one pendulum swing arm. A latching mechanism extends between the frame and the at least one pendulum swing arm, and engages the at least one pendulum swing arm when the carriage assembly is in a lowered position, raises the carriage assembly to a raised positon, and disengages the at least one pendulum swing arm at the raised positon so that the carriage assembly strikes a pallet. A sensor generates a signal corresponding to how high the carriage assembly is raised. A controller operates the latching mechanism, including disengaging the at least one pendulum swing arm when a height of the carriage assembly corresponds to a desired release height so that a predetermined impact force strikes the pallet.

Abstract: Apparatus and method for aligning a rotatable substrate to a support mechanism to write a feature to the substrate, and a substrate so configured. In some embodiments, the substrate has a circumferentially extending timing pattern with spaced apart first and second timing marks disposed on opposing sides of a center point of the timing pattern and an identification (ID) field that stores a unique identifier value associated with the substrate. Upon mounting of the substrate to a support mechanism that rotates the substrate about a central axis that is offset from the center point, a control circuit generates a compensation value to compensate for the offset using the first and second timing marks and outputs a process instruction to authorize processing of the substrate using the unique identifier value. In some cases, the unique identifier value is used as a lookup to a computerized database.

Abstract: Apparatus and method for aligning a rotatable substrate to a support mechanism to write a feature to the substrate, and a substrate so configured. In some embodiments, the substrate has a circumferentially extending timing pattern with spaced apart first and second timing marks disposed on opposing sides of a center point of the timing pattern and an identification (ID) field that stores a unique identifier value associated with the substrate. Upon mounting of the substrate to a support mechanism that rotates the substrate about a central axis that is offset from the center point, a control circuit generates a compensation value to compensate for the offset using the first and second timing marks and outputs a process instruction to authorize processing of the substrate using the unique identifier value. In some cases, the unique identifier value is used as a lookup to a computerized database.