FINGER JOINER TRAINING

Operating the Laminate Press (FJ Press)

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Introduction

The Laminate Press is an essential part of the Finger Jointer Workstation, where glued timber pieces are pressed together to form high-quality laminated beams. After the finger joints are cut and glued, the timber is aligned and transferred to the Laminate Press, where it is pressed under high pressure to ensure strong, durable joints. This lesson will guide you through the process of operating the Laminate Press, from transferring the timber to pressing and inspecting the final product.

By the end of this lesson, you will be able to:

Safely transfer timber to the Laminate Press.
Set up and operate the press.
Monitor the pressing process to ensure proper bonding and alignment.
Handle common issues that may arise during operation.

Step-by-Step Process for Operating the Laminate Press

Step 1: Transferring Timber to the Laminate Press

After the timber pieces have been glued and joined, they need to be aligned and transferred to the Laminate Press.

Ensure Proper Alignment on Threading Chains:
- Before transferring the timber, ensure that the threading chains have aligned the timber correctly. Misalignment can cause poor bonding or defective joints.
- Monitor the Photo Electric (PE) eyes on the threading chains to ensure proper movement and alignment of the timber.
Activate Transfer to Laminate Press:
- Using the control panel, activate the transfer mechanism that moves the timber from the Auto Flipper or Threading Chains into the Laminate Press.
- Verify that the transfer occurs smoothly and without any jams. If a jam occurs, stop the transfer and clear the obstruction before restarting.

Step 2: Setting Up the Laminate Press

Once the timber is in place, you will need to set up the Laminate Press to ensure the correct pressure is applied to bond the timber pieces together.

Set the Pressing Parameters:
- Using the Human-Machine Interface (HMI), input the required pressing parameters, such as pressing force and press time, based on the timber size and job specifications.
- Ensure the settings match the job sheet to avoid under- or over-pressing, which could affect the strength of the joints.
Check Glue Coverage:
- Before pressing begins, verify that the glue applied during the previous step is distributed evenly across the timber joints. This ensures a proper bond once the press is activated.
Ensure Timber Alignment:
- Double-check that the timber is perfectly aligned in the press. Misaligned timber can result in weak joints or deformed beams, which must be removed and reprocessed.

Step 3: Operating the Laminate Press

Once the timber is correctly aligned and all settings are configured, you can begin the pressing process.

Activate the Laminate Press:
- Press the start button on the HMI to activate the Laminate Press.
- The press will apply pressure to the timber, joining the glued ends together and ensuring a strong bond between the pieces.
Monitor the Pressing Process:
- Throughout the pressing process, monitor the pressure levels and the position of the timber to ensure everything is running smoothly.
- Use the HMI to check the current pressure and pressing time. If the pressure drops or exceeds the specified levels, stop the press and inspect the system for any issues.
- Ensure that the timber is being pressed evenly across its entire length.

Step 4: Final Checks and Beam Inspection

After the press completes its cycle, it’s important to inspect the laminated beams to ensure they meet quality standards.

Release the Press:
- Once the pressing cycle is complete, release the pressure and carefully disengage the press. Ensure that the timber is released smoothly without any damage.
Inspect the Laminated Beams:
- Conduct a visual inspection of the laminated beams to check for defects such as insufficient glue squeeze-out, stepped joints, or misaligned timber.
- Check the strength of the bonds by inspecting the joints for any visible gaps or weak points.
- If any defects are detected, set aside the defective beams for rework or disposal.

Step 5: Transferring Beams to the Laminate Decks

Once the laminated beams have been inspected, they need to be transferred to the Laminate Decks for drying.

Activate the Transfer Mechanism:
- Use the control panel to activate the transfer mechanism that moves the beams from the Laminate Press to the Laminate Decks.
- Monitor the transfer to ensure that the beams are placed correctly on the decks and that there are no jams or misalignment issues.
Ensure Proper Placement on the Laminate Decks:
- The beams must be placed on the decks in a way that allows them to dry evenly. Ensure that the beams are spaced properly and that the air can circulate around them for uniform drying.

Step 6: Handling Common Issues

Operating the Laminate Press requires continuous monitoring to avoid issues that can affect the quality of the beams. Below are some common issues and how to handle them:

Misaligned Timber:
- If the timber is not aligned properly during the pressing process, the joints may be weak or defective. If misalignment is detected, stop the press, realign the timber, and restart the process.
Insufficient Pressing Force:
- If the pressing force is too low, the timber may not bond correctly. Monitor the pressure during the pressing process, and if necessary, adjust the pressing parameters on the HMI.
Excessive Glue Squeeze-Out:
- If too much glue is being squeezed out during the pressing process, this could indicate that too much glue was applied earlier. Clean the excess glue and ensure that the glue applicator is functioning correctly for the next batch.
Jams in the Transfer Mechanism:
- If a jam occurs during the transfer process, stop the machine immediately using the E-stop. Clear the obstruction before restarting the transfer process.

Conclusion

Operating the Laminate Press is a crucial step in the production of high-quality laminated beams. By following the steps outlined in this lesson, you can ensure that the timber is properly pressed, bonded, and transferred for drying without defects. Continuously monitor the process, check for common issues, and perform final inspections to maintain high standards of quality.

In the next lessons, you will learn how to handle size changes, conduct detailed quality control, and complete post-operational checks for the workstation. Always remember to prioritize safety and follow the correct procedures for smooth and efficient operations.

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Planer Control Panel

Planer Setup

Set laminate size according to the program sheets specific thickness. Ensure exact accuracy using the calibrated Vernier calipers as a minor error can multiply across multiple laminates in a beam. Ensure a good quality surface finish to provide a quality gluing surface.

Monitoring the Process

Monitoring Feed Consistency:

Step 1: Monitor the feed rollers as they guide the laminates into the planer. Ensure that the rollers maintain a firm grip on the laminates without causing slippage or misalignment.

Step 2: Adjust the feed speed using the Feed Speed Dial on the control panel if necessary. The speed should be set based on the type of laminate and the desired surface finish.

4.2.2 Monitoring the Process

Process Monitoring:

Step 1: Continuously monitor the planer’s operation by observing the laminates as they pass through the machine. Look for signs of improper cutting, such as rough surfaces, uneven thickness, or any visible defects.

Step 2: Listen for unusual noises that may indicate issues with the knives, rollers, or other components. Any unusual sounds should be investigated immediately to prevent potential damage to the machine or the laminates.

Adjusting Planer Settings:

Step 1: If you notice any inconsistencies in the laminate finish, pause the operation and make necessary adjustments to the cutter heads, feed rollers, or other settings. This may include adjusting the pressure of the rollers or re-aligning the cutters.

Step 2: Use the touchscreen control panel to make fine adjustments to the planer settings. Ensure that these adjustments are based on observed issues and are aimed at improving the laminate quality.

HSP Quality Checks and Escalation Process

Quality checks are essential to ensure that laminates produced by the High-Speed Planer (HSP) meet the required specifications. Operators and wood machinists are responsible for conducting these checks at regular intervals, particularly during size changes or every 4th press load. Any issues outside the set tolerances must be escalated and resolved to maintain production quality.

1. Lamella Thickness Check

How to Perform: Use calibrated Vernier calipers to measure four points along both sides of the lamella.
Frequency: Every size change or every 4th press load.
Target and Tolerance: Target is -0mm to +0.2mm.
Action if Out of Range:
- Make thickness adjustments via the console if needed.
- Escalation: If console adjustments cannot resolve the issue, immediately stop production and inform the wood machinist and supervisor.
- Further notify the Supervisor and EWP Quality Coordinator if undersized material is frequently observed.

2. Lamella Width Check

How to Perform: Use calibrated Vernier calipers to measure four points along the width of the lamella.
Frequency: Every size change or every 4th press load.
Action if Out of Range:
- Inform the wood machinist of any width issues before using the console to make minor adjustments.
- Escalation: If the console cannot solve the issue, cease production and notify the supervisor and wood machinists. Further action is required if undersized material continues to appear.

3. Lamella Squareness Check

How to Perform: Use a square to measure four points along the lamella’s width, checking for gaps between the square and the lamella.
Frequency: Every size change or every 4th press load.
Target and Tolerance: Maximum tolerance is 0.1mm per 100mm of width.
Action if Out of Range:
- Adjust the planer head installation to ensure even planing and check for knife wear.
- Escalation: If adjusting the head and replacing the knives doesn’t solve the issue, stop production and notify maintenance to inspect the planer and check bed levels.

4. Correct Cut Amount (Top and Bottom)

How to Perform: Mark the center of a test board, then measure the distance from the center to the top and bottom. After planing, remeasure and calculate the differences to ensure consistency.
Frequency: Every size change or every 4th press load.
Target and Tolerance: ±0.5mm.
Action if Out of Range:
- Adjustments should be made via the bottom head infeed plate.
- Escalation: If adjustments don’t resolve the issue, cease production and notify the supervisor. A head change or full realignment of the planer may be required.

5. Riptec Finish Check

How to Perform: Visually inspect the length of the planed lamella to ensure the riptec finish is straight and even.
Frequency: Every size change or every 4th press load.
Action if Out of Range:
- Check for waves or thick/thin points in the riptec finish.
- Escalation: If issues are present, stop production and notify the wood machinist and supervisor. Cutter adjustment or replacement may be necessary.

Escalation Process

If any of the above checks reveal issues that cannot be resolved through standard console adjustments or minor corrective actions, escalate the issue by:

Stopping production immediately.
Notifying the wood machinist and supervisor of the problem.
If the issue is recurring (e.g., frequent undersized material), report it to the EWP Quality Coordinator for further investigation and adjustments at the infeed grading station.

These quality checks help ensure that all products processed through the HSP meet the required specifications, maintaining high standards and avoiding defects in the final laminated beams. Operators are responsible for performing these checks diligently and escalating any issues promptly to avoid production downtime or compromised quality.

Addressing Common Issues

4.2.3 Addressing Common Issues

Dealing with Planer Jams:

Step 1: If a jam occurs, immediately stop the planer using the Emergency Stop (E-STOP) button. Never attempt to clear a jam while the machine is running.

Step 2: Carefully clear the jam by removing any obstructing laminates or debris. Check the feed rollers and infeed area for any issues that may have caused the jam, such as misalignment or foreign objects.

Managing Poor Surface Finish:

Step 1: If laminates emerge with a poor surface finish, inspect the knives and cutter heads for sharpness and alignment. Dull or misaligned knives can cause rough surfaces.

Step 2: Adjust the planer settings to increase the quality of the cut, which may involve lowering the feed speed or adjusting the pressure of the feed rollers.

Handling Inconsistent Laminate Size:

Step 1: If the laminate thickness or width is inconsistent, pause the operation and re-calibrate the planer. Run additional test pieces to ensure that the adjustments have corrected the issue.

Step 2: Document any persistent issues and report them to your supervisor or maintenance team for further investigation.

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