Abstract: A truss-jig-positioning system that includes a truss-assembly table having a support plane, a plurality of slots in the support plane, and a plurality of puck assemblies automatically movable along the slots. Each puck is self-powered and self-locks at selected locations. A controller controls the pucks. Images of the truss-assembly table and pucks allow the controller to locate pucks, and transmit location-correction information as needed to move pucks to desired locations for building various trusses, wall assemblies, etc. Pucks are self-powered, self-moving, motorized jigging members. Each operates from controller commands to unlock from one location, move along their slot and lock to a new location. Optionally location-measuring (machine-vision) subsystem(s) communicate wirelessly with the pucks to readjust positions and re-lock at the adjusted position.

Abstract: A system that includes a computer processor having a plurality of input data devices, a plurality of output data devices, and a plurality of sensors; and a mechanical assembly integrated with the computer processor to reposition a piece of wood lumber based on software code executing in the computer processor. In some embodiments, the system performs a method that includes eliciting and receiving into the computer processor data parameters from a first human user; obtaining incoming data points about the lumber from the plurality of sensors; processing and storing the data parameters; comparing the incoming data points to the data parameters to obtain comparison results; and, based on the comparison results, (1) rejecting the lumber to a preprogrammed position, (2) feeding the lumber into a saw assembly as positioned, or (3) repositioning the lumber to a more optimal position prior to feeding the lumber to the saw assembly.

Abstract: A method and apparatus for assembling components of a workpiece. Some embodiments include a work surface; a first digital projector that projects an image of at least some features of the workpiece onto the work surface, wherein the image includes a plurality of line indicators that have visually discernible different markings such as colors or line types; a camera that obtains input images of the work surface and the components of the workpiece; and a first controller configured to receive the input images from the camera and to control the first digital projector to project the first output digital image on the work surface for assembly of the components to form the workpiece, wherein the first controller is further configured to store distortion-correction parameters and to use the stored distortion-correction parameters to adjust the first projected output digital image. In some embodiments, the workpiece is a lumber truss.

Abstract: A system including a gantry structure; a first and a second saw head movable along at least part of the length of the gantry structure; and a first and a second lumber support also movable along corresponding lengths of the gantry structure. A controller moves the first saw head and first lumber support adjacent a first location along a board and moves the second saw head and second lumber support adjacent a second location along a board, and operates the first and second saw heads to cut first and second ends off the board. The controller then moves the saw heads and the lumber supports relative to the board to third and fourth locations and operates the first and second saw heads to cut third and fourth end pieces off. The saw heads and lumber supports optionally move together and rotate around respective vertical axes to enable angled board cuts.

Abstract: A method and apparatus for assembling components of a workpiece. Some embodiments include a work surface; a first digital projector that projects an image of at least some features of the workpiece onto the work surface, wherein the image includes a plurality of line indicators that have visually discernible different markings such as colors or line types; a camera that obtains input images of the work surface and the components of the workpiece; and a first controller configured to receive the input images from the camera and to control the first digital projector to project the first output digital image on the work surface for assembly of the components to form the workpiece, wherein the first controller is further configured to store distortion-correction parameters and to use the stored distortion-correction parameters to adjust the first projected output digital image. In some embodiments, the workpiece is a lumber truss.

Abstract: A truss-jig-positioning system that includes a truss-assembly table having a support plane, a plurality of slots in the support plane, and a plurality of puck assemblies automatically movable along the slots. Each puck is self-powered and self-locks at selected locations. A controller controls the pucks. Images of the truss-assembly table and pucks allow the controller to locate pucks, and transmit location-correction information as needed to move pucks to desired locations for building various trusses, wall assemblies, etc. Pucks are self-powered, self-moving, motorized jigging members. Each operates from controller commands to unlock from one location, move along their slot and lock to a new location. Optionally location-measuring (machine-vision) subsystem(s) communicate wirelessly with the pucks to readjust positions and re-lock at the adjusted position.

Abstract: A system that includes a computer processor having a plurality of input data devices, a plurality of output data devices, and a plurality of sensors; and a mechanical assembly integrated with the computer processor to reposition a piece of wood lumber based on software code executing in the computer processor. In some embodiments, the system performs a method that includes eliciting and receiving into the computer processor data parameters from a first human user; obtaining incoming data points about the lumber from the plurality of sensors; processing and storing the data parameters; comparing the incoming data points to the data parameters to obtain comparison results; and, based on the comparison results, (1) rejecting the lumber to a preprogrammed position, (2) feeding the lumber into a saw assembly as positioned, or (3) repositioning the lumber to a more optimal position prior to feeding the lumber to the saw assembly.

Abstract: A system including a lumber-pickup arm having a plurality of suction cups in a staggered configuration to pick up a piece of lumber that may be cracked, crooked or askew on the pile of lumber from which it is to be picked. In some embodiments, the system performs a method that includes locating a selected piece of lumber to be picked up; lowering the pickup arm so that at least some of the plurality of suction cups are seated on a first surface of the selected piece of lumber; reducing air pressure within the at least some of the plurality of suction cups; raising and moving the pickup arm to move the piece of lumber to a first destination; and increasing air pressure within the at least some of the plurality of suction cups to release the piece of lumber at the first destination Cups not holding vacuum are deactivated.

Abstract: An automated lumber handling system laser-scans the top profile of multiple stacks of lumber, each of which contain boards of a unique size. Based on the scanned profiles, the system determines the order in which individual boards from a chosen stack should be transferred to a saw. The saw cuts the boards to size and in proper sequence to facilitate orderly assembly of roof trusses or prefabricated walls. Some example systems lift individual boards by driving two screws, or some other piercing tool, down into the upward facing surface of the board. A track mounted cantilever, holding the screws and a laser unit, translates over the lumber stacks to retrieve and deliver individual boards and, while doing so, the laser repeatedly scans the stacked lumber profiles on-the-fly to continuously update the profiles. The open cantilever design facilitates replenishing the stacks of lumber.

Abstract: An automated lumber handling system laser-scans the top profile of multiple stacks of lumber, each of which contain boards of a unique size. Based on the scanned profiles, the system determines the order in which individual boards from a chosen stack should be transferred to a numerically controlled saw. The saw cuts the boards to proper size and in the proper sequence to facilitate orderly assembly of a roof truss or prefabricated wall. In some examples, the system lifts individual boards by driving two retractable screws, or some other piercing tool, down into the upward facing surface of the board. A track mounted cantilever, holding the screws and a laser unit, translates over the lumber stacks to retrieve and deliver individual boards and, while doing so, the laser repeatedly scans the stacked lumber profiles on-the-fly to continuously update the profiles. The open cantilever design facilitates replenishing the stacks of lumber.

Abstract: A system that includes a computer processor having a plurality of input data devices, a plurality of output data devices, and a plurality of sensors; and a mechanical assembly integrated with the computer processor to reposition a piece of wood lumber based on software code executing in the computer processor. In some embodiments, the system performs a method that includes eliciting and receiving into the computer processor data parameters from a first human user; obtaining incoming data points about the lumber from the plurality of sensors; processing and storing the data parameters; comparing the incoming data points to the data parameters to obtain comparison results; and, based on the comparison results, (1) rejecting the lumber to a preprogrammed position, (2) feeding the lumber into a saw assembly as positioned, or (3) repositioning the lumber to a more optimal position prior to feeding the lumber to the saw assembly.

Abstract: A method and apparatus for assembling components of a workpiece. Some embodiments include a work surface; a first digital projector that projects an image of at least some features of the workpiece onto the work surface, wherein the image includes a plurality of line indicators that have visually discernible different markings such as colors or line types; a camera that obtains input images of the work surface and the components of the workpiece; and a first controller configured to receive the input images from the camera and to control the first digital projector to project the first output digital image on the work surface for assembly of the components to form the workpiece, wherein the first controller is further configured to store distortion-correction parameters and to use the stored distortion-correction parameters to adjust the first projected output digital image. In some embodiments, the workpiece is a lumber truss.

Abstract: A system including a gantry structure; a first and a second saw head movable along at least part of the length of the gantry structure; and a first and a second lumber support also movable along corresponding lengths of the gantry structure. A controller moves the first saw head and first lumber support adjacent a first location along a board and moves the second saw head and second lumber support adjacent a second location along a board, and operates the first and second saw heads to cut first and second ends off the board. The controller then moves the saw heads and the lumber supports relative to the board to third and fourth locations and operates the first and second saw heads to cut third and fourth end pieces off. The saw heads and lumber supports optionally move together and rotate around respective vertical axes to enable angled board cuts.

Abstract: A system that includes a computer processor having a plurality of input data devices, a plurality of output data devices, and a plurality of sensors; and a mechanical assembly integrated with the computer processor to reposition a piece of wood lumber based on software code executing in the computer processor. In some embodiments, the system performs a method that includes eliciting and receiving into the computer processor data parameters from a first human user; obtaining incoming data points about the lumber from the plurality of sensors; processing and storing the data parameters; comparing the incoming data points to the data parameters to obtain comparison results; and, based on the comparison results, (1) rejecting the lumber to a preprogrammed position, (2) feeding the lumber into a saw assembly as positioned, or (3) repositioning the lumber to a more optimal position prior to feeding the lumber to the saw assembly.

Abstract: An automated lumber handling system laser-scans the top profile of multiple stacks of lumber, each of which contain boards of a unique size. Based on the scanned profiles, the system determines the order in which individual boards from a chosen stack should be transferred to a numerically controlled saw. The saw cuts the boards to proper size and in the proper sequence to facilitate orderly assembly of a roof truss or prefabricated wall. In some examples, the system lifts individual boards by driving two retractable screws, or some other piercing tool, down into the upward facing surface of the board. A track mounted cantilever, holding the screws and a laser unit, translates over the lumber stacks to retrieve and deliver individual boards and, while doing so, the laser repeatedly scans the stacked lumber profiles on-the-fly to continuously update the profiles. The open cantilever design facilitates replenishing the stacks of lumber.

Abstract: An automated lumber handling system laser-scans the top profile of multiple stacks of lumber, each of which contain boards of a unique size. Based on the scanned profiles, the system determines the order in which individual boards from a chosen stack should be transferred to a numerically controlled saw. The saw cuts the boards to proper size, and in the proper sequence to facilitate orderly assembly of a roof truss or prefabricated wall. In some examples, the system lifts individual boards by driving two retractable screws, or some other piercing tool, down into the upward facing surface of the board. A track mounted cantilever, holding the screws and a laser unit, translates over the lumber stacks to retrieve and deliver individual boards and, while doing so, the laser repeatedly scans the stacked lumber profiles on-the-fly to continuously update the profiles. The open cantilever design facilitates replenishing the stacks of lumber.