System and method for evaluating edge hardness of cementitious boards and system for stacking cementitious boards inlcuding same

{
  "publication_number": "US10564081B2",
  "country": "US",
  "kind": "B2",
  "title": "System and method for evaluating edge hardness of cementitious boards and system for stacking cementitious boards inlcuding same",
  "abstract": "Embodiments of a system and a method for determining an edge hardness value for a cementitious board can be used to effectively determine the hardness of the board after it has been made and dried at a predetermined location, such as, at a stacking station, for example. An actuator assembly can manipulate a punch such that the punch is inserted into one of the edges of one of the cementitious boards in the stacker in a controlled manner. A force gauge can be associated with the punch to measure the resistance force exerted by the cementitious board in response to the punch being inserted into its edge. The measured resistance force can be used to determine the edge hardness value.",
  "claims": [
    "1. A system for determining an edge hardness value of a cementitious board, the cementitious board having a cementitious core formed from aqueous cementitious slurry, the cementitious board having first and second faces with a length extending along a longitudinal axis and a width extending along a transverse axis that is perpendicular to the longitudinal axis, and first and second edges with a thickness extending along a normal axis that is perpendicular to both the longitudinal axis and the transverse axis, the system comprising: a support fixture, the support fixture having a support surface configured to support the cementitious board such that the first and second faces are generally parallel to the support surface; a punch, the punch having a distal portion with a distal end, the distal portion being cylindrical; an actuator assembly, the actuator assembly including a first actuator and a second actuator, the second actuator supporting the punch, the first actuator being configured to move the punch along the normal axis relative to the cementitious board supported in the support fixture to adjust a normal position of the punch relative to the thickness of the cementitious board, and the second actuator being configured to move the punch along the transverse axis relative to the cementitious board supported in the support fixture to adjust a transverse position of the punch relative to the width of the cementitious board, the second actuator being configured to reciprocally move the punch along the transverse axis over a measurement stroke between a home position, in which the distal end of the punch is in offset relationship to the cementitious board supported in the support fixture, and a measurement position, in which the distal end of the punch is in interfering relationship with the cementitious board supported in the support fixture, such that the second actuator is configured to drive the distal end of the punch into one of the first and second edges of the cementitious board supported in the support fixture when the punch moves from the home position to the measurement position; a force gauge, the force gauge supported by the second actuator of the actuator assembly and interposed between the punch and the second actuator, the force gauge configured to measure a resistance force exerted against the punch by the cementitious board in response to the distal end of the punch being inserted into the edge of the cementitious board, the force gauge configured to generate a force signal indicative of the resistance force; a processor, the processor in communication with the force gauge to receive the force signal therefrom, the processor programmed with an edge hardness measurement program stored on a non-transitory computer readable medium, the edge hardness measurement program being configured to use the force signal to determine the edge hardness value for the cementitious board.",
    "2. The system according to claim 1, wherein the edge hardness measurement program is configured to determine the edge hardness value based upon a peak load of the resistance force measured by the force gauge as the punch moves from the home position to the measurement position.",
    "3. The system according to claim 1, further comprising: a controller, the controller being in operable arrangement with the actuator assembly, the controller configured to selectively operate the second actuator of the actuator assembly to reciprocally move the punch along the transverse axis over the measurement stroke.",
    "4. The system according to claim 3, further comprising: a board detection system, the board detection system being configured to detect the position of the cementitious board supported in the support fixture along the normal axis, the board detection system configured to generate a board position signal indicative of the position of the cementitious board along the normal axis; wherein the controller is in communication with the board detection system to receive the board position signal therefrom, the controller configured to selectively operate the first actuator of the actuator assembly based upon the board position signal to move the punch along the normal axis to position the punch along the normal axis within the thickness of the cementitious board.",
    "5. A stacking system for stacking a plurality of cementitious boards, each cementitious board having a cementitious core formed from an aqueous cementitious slurry, the cementitious board having first and second faces with a length extending along a longitudinal axis and a width extending along a transverse axis that is perpendicular to the longitudinal axis, and having first and second edges with a thickness extending along a normal axis that is perpendicular to both the longitudinal axis and the transverse axis, the stacking system comprising: a lift assembly, the lift assembly being configured to support the cementitious boards in a stacked arrangement upon the support surface, the lift assembly including a support fixture and a hoist, the support fixture having a support surface configured to support the cementitious boards such that the first and second faces of the cementitious boards are generally parallel to the support surface, and the hoist being connected to the support fixture and adapted to move the support fixture over a range of travel along the normal axis; a conveyor, the conveyor configured to serially convey the cementitious boards to a position over the lift assembly for being placed upon the support surface; a punch, the punch having a distal portion with a distal end, the distal portion being cylindrical; an actuator assembly, the actuator assembly being configured to reciprocally move the punch along the transverse axis relative to the support fixture over a measurement stroke between a home position, in which the distal end of the punch is in offset relationship to the cementitious boards supported in the support fixture, and a measurement position, in which the distal end of the punch is in interfering relationship with one of the cementitious boards supported in the support fixture, such that the actuator assembly drives the distal end of the punch into one of the first and second edges of said cementitious board when the punch moves from the home position to the measurement position; a force gauge, the force gauge supported by the actuator assembly and interposed between the punch and the actuator assembly, the force gauge configured to measure a resistance force exerted against the punch by said cementitious board in response to the distal end of the punch being inserted into the edge of said cementitious board, the force gauge configured to generate a force signal indicative of the resistance force; a processor, the processor in communication with the force gauge to receive the force signal therefrom, the processor programmed with an edge hardness measurement program stored on a non-transitory computer readable medium, the edge hardness measurement program being configured to use the force signal to determine the edge hardness value for the cementitious board.",
    "6. The stacking system according to claim 5, wherein the edge hardness measurement program is configured to determine the edge hardness value based upon a peak load of the resistance force measured by the force gauge as the punch moves from the home position to the measurement position.",
    "7. The stacking system according to claim 5, further comprising: a backstop member, the backstop member positioned to stop the cementitious board from being moved via the conveyor such that the cementitious board is stopped at the position over the support surface of the lift assembly.",
    "8. The stacking system according to claim 7, wherein the actuator assembly is mounted to the backstop member.",
    "9. The stacking system according to claim 5, further comprising: a controller, the controller being in operable arrangement with the actuator assembly, the controller configured to selectively operate the actuator assembly to reciprocally move the punch along the transverse axis over the measurement stroke.",
    "10. The stacking system according to claim 9, wherein the actuator assembly includes a first actuator and a second actuator, the second actuator supporting the punch, the first actuator being configured to move the punch along the normal axis relative to the cementitious board supported in the support fixture to adjust the position of the punch relative to the thickness of the cementitious board, and the second actuator being configured to move the punch along the transverse axis relative to the cementitious board supported in the support fixture to adjust the position of the punch relative to the width of the cementitious board, the second actuator being configured to reciprocally move the punch along the transverse axis over the measurement stroke, and the force gauge is supported by the second actuator and is interposed between the punch and the second actuator.",
    "11. The stacking system according to claim 10, further comprising: a board detection system, the board detection system being configured to detect the position of the cementitious board supported in the support fixture along the normal axis, and the board detection system being configured to generate a board position signal indicative of the position of the cementitious board along the normal axis; wherein the controller is in communication with the board detection system to receive the board position signal therefrom, the controller being configured to selectively operate the first actuator of the actuator assembly based upon the board position signal to move the punch along the normal axis to position the punch along the normal axis within the thickness of the cementitious board.",
    "12. The stacking system according to claim 11, wherein the first face of the cementitious boards includes a pair of tapered portions respectively adjacent the first and second edges such that each cementitious board is asymmetrical about the transverse axis, and the board detection system is configured to detect the orientation of the first and second edges of the cementitious board supported in the support fixture relative to the punch and to generate a board orientation signal indicative of the orientation of the first and second edges of the cementitious board with respect to the punch to indicate which of the first and second edges of said cementitious board the punch is inserted into when the punch moves from the home position to the measurement position.",
    "13. The stacking system according to claim 12, wherein the board detection system is configured to detect a center position along the normal axis between a pair of booked cementitious boards supported by the support fixture, the booked cementitious boards being in contacting relationship with each other such that the first edge of one cementitious board is aligned with the second edge of the other cementitious board, and the position signal the board detection system is configured to generate is a booked pair position signal indicative of the center position along the normal axis of the pair of booked cementitious boards, and wherein the controller is in communication with the board detection system to receive the booked pair position signal therefrom, the controller being configured to serially: operate the first actuator of the actuator assembly based upon the booked pair position signal to move the punch along the normal axis to position the punch in a first pair position along the normal axis within the thickness of one of the pair of booked cementitious boards, operate the second actuator of the actuator assembly to reciprocally move the punch along the transverse axis over the measurement stroke, operate the first actuator of the actuator assembly based upon the booked pair position signal to move the punch along the normal axis to position the punch in a second pair position along the normal axis within the thickness of the other of the pair of booked cementitious boards, and operate the second actuator of the actuator assembly to reciprocally move the punch along the transverse axis over the measurement stroke.",
    "14. A method of determining an edge hardness value of a cementitious board, the cementitious board having a cementitious core formed from aqueous cementitious slurry, the cementitious board having first and second faces with a length extending along a longitudinal axis and a width extending along a transverse axis that is perpendicular to the longitudinal axis, and having first and second edges with a thickness extending along a normal axis that is perpendicular to both the longitudinal axis and the transverse axis, the method comprising: conveying the cementitious board to a position over a support surface of a lift assembly such that the support surface supports the cementitious board with the first and second faces being generally parallel to the support surface; positioning a punch along the normal axis relative to the cementitious board supported by the support surface such that the punch is positioned along the normal axis within the thickness of the cementitious board; moving the punch along the transverse axis relative to the cementitious board supported by the support surface over a measurement stroke between a home position, in which a distal end of the punch is in offset relationship to the cementitious board, and a measurement position, in which the distal end of the punch is in interfering relationship with the cementitious board, such that the distal end of the punch is inserted into one of the first and second edges of said cementitious board when the punch is in the measurement position; measuring a resistance force exerted by the cementitious board against the punch in response to the punch being inserted into one of the first and second edges of said cementitious board; transmitting a force signal to a processor, the force signal indicative of the measured resistance force; executing an edge hardness measurement program stored upon a non-transitory computer-readable medium using the processor to determine the edge hardness value for the cementitious board based upon the force signal.",
    "15. The method according to claim 14, further comprising: displaying the edge hardness value in a display device operably arranged with the processor via a graphical user interface.",
    "16. The method according to claim 14, wherein the edge hardness measurement program determines the edge hardness value based upon a peak load of the measured resistance force as the punch moves from the home position to the measurement position.",
    "17. The method according to claim 14, wherein the first face of the cementitious board includes a pair of tapered portions respectively adjacent the first and second edges such that each cementitious board is asymmetrical about the transverse axis, and the method further comprising: detecting the orientation of the first and second edges of the cementitious board supported by the support surface relative to the punch; transmitting a board orientation signal to the processor, the board orientation signal indicative of the orientation of the first and second edges of the cementitious board with respect to the punch to indicate into which one of the first and second edges the punch was inserted.",
    "18. The method according to claim 14, further comprising: lowering the support surface of the lift assembly relative to a conveyor along the normal axis; conveying a pair of booked cementitious boards to the position over the support surface of the lift assembly such that the support surface supports the pair of booked cementitious boards in a stacked arrangement upon the support surface.",
    "19. The method according to claim 18, further comprising: detecting the position along the normal axis of one of the cementitious boards in the stacked arrangement upon the support surface; transmitting a board position signal to a controller, the board position signal indicative of the position of said cementitious board along the normal axis; using the controller to move the punch along the normal axis based upon the board position signal to position the punch along the normal axis within the thickness of said cementitious board.",
    "20. The method according to claim 18, wherein the first face of each of the pair of booked cementitious boards includes a pair of tapered portions respectively adjacent the first and second edges such that each of the booked cementitious boards is asymmetrical about the transverse axis, the pair of booked cementitious boards being in contacting relationship with each other such that the first edge of one cementitious board is aligned with the second edge of the other cementitious board, and the method further comprising: detecting a center position along the normal axis between the pair of booked cementitious boards supported by the support fixture; transmitting a booked pair position signal to a controller, the booked pair position signal indicative of the center position along the normal axis of the pair of booked cementitious boards; detecting the orientation of the first and second edges of the pair of booked cementitious boards supported by the support surface relative to the punch; transmitting a board orientation signal to the processor, the board orientation signal indicative of the orientation of the first and second edges of the pair of booked cementitious boards with respect to the punch; using the controller to move the punch along the normal axis based upon the booked pair position signal to position the punch in a first pair position along the normal axis within the thickness of a first one of the pair of booked cementitious boards having the first edge adjacent the punch; reciprocally moving the punch along the transverse axis over the measurement stroke for a first edge hardness measurement of the first edge of the first one of the pair of booked cementitious boards; measuring the resistance force exerted by the first one of the pair of booked cementitious boards against the punch in response to the punch being inserted into the first edge of the first one of the pair of booked cementitious boards; transmitting the force signal relating to the first edge hardness measurement to the processor, the force signal indicative of the measured resistance force for the first edge hardness measurement; using the controller to move the punch along the normal axis based upon the booked pair position signal to position the punch in a second pair position along the normal axis within the thickness of the other one of the pair of booked cementitious boards having the second edge adjacent the punch; reciprocally moving the punch along the transverse axis over the measurement stroke for a second edge hardness measurement of the second edge of the other one of the pair of booked cementitious boards; measuring the resistance force exerted by the other one of the pair of booked cementitious boards against the punch in response to the punch being inserted into the second edge of the other cementitious board; transmitting the force signal relating to the second edge hardness measurement to the processor, the force signal indicative of the measured resistance force for the second edge hardness measurement."
  ],
  "description_excerpt": "The present disclosure relates to cementitious board manufacturing processes and, more particularly, to systems and methods for measuring the hardness of the edge of a cementitious board after its manufacture.\n\nIn many types of cementitious articles, set gypsum (calcium sulfate dihydrate) is often a major constituent. For example, set gypsum is a major component of end products created by use of traditional plasters (e.g., plaster-surfaced internal building walls), and also in faced gypsum board employed in typical drywall construction of interior walls and ceilings of buildings. In addition, set gypsum is the major component of gypsum/cellulose fiber composite boards and products, as described in U.S. Pat. No. 5,320,677, for example. Typically, such gypsum-containing cementitious products are made by preparing a mixture of calcined gypsum (calcium sulfate alpha or beta hemihydrate and/or calcium sulfate anhydrite), water, and other components, as appropriate to form cementitious slurry. The cementitious slurry and desired additives are often blended in a continuous mixer, as described in U.S. Pat. No. 3,359,146, for example.\n\nIn a typical cementitious board manufacturing process such as gypsum wallboard, cementitious board is produced by uniformly dispersing calcined gypsum (commonly referred to as “stucco”) in water to form aqueous calcined gypsum slurry. The aqueous calcined gypsum slurry is typically produced in a continuous manner by inserting stucco and water and other additives into a mixer which contains means for agitating the contents to form a uniform gypsum slurry.",
  "cpc": [
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    "B65G 57/035",
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    "B65G 57/11",
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  "ipc": [
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  ],
  "assignees": [
    "United States Gypsum Co"
  ],
  "inventors": [
    "Leslie Eversole",
    "Colin J. FAHEY",
    "Thomas Boyer",
    "Craig Thomas WATSON"
  ],
  "filing_date": "2017-10-10",
  "publication_date": "2020-02-18",
  "grant_date": "2020-02-18",
  "priority_date": "2017-02-03",
  "application_number": "US-201715729398-A",
  "family_id": "63037102",
  "cited_by_count": 3,
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