The specialized end bar machine was a custom-built, six-motor automated unit designed to perform multiple woodworking operations simultaneously. It functioned by feeding blanks vertically, drilling four holes, cutting specific dados on both the top and bottom ends, and shaping the bar's profile using jointer heads.
This machine's sophisticated automation allowed it to consolidate complex shaping and drilling tasks into a single high-speed process, delivering finished components at a rate of two per second.
Automated Operational Sequence
Vertical Feeding and Positioning
The process began with an automated feeding mechanism. This system oriented the raw blanks into a vertical position to prepare them for the subsequent machining steps.
Precision Drilling
Once positioned, the machine engaged its drilling apparatus. It simultaneously bored four holes into the bar, likely intended for wiring or assembly hardware.
Dado Cutting Specifications
The machine performed precise joinery cuts on both ends of the bar. It cut a 1 1/16-inch wide dado on the top end and a 5/8-inch wide dado on the bottom end.
Both the top and bottom dados were cut to a uniform depth of 3/8 inch, ensuring consistent fitment for the frames.
Profile Shaping (Jointing)
To finalize the shape of the end bar, the machine utilized two separate jointer heads.
These heads removed 3/16 inch of material from the bar's surface. This reduction was applied specifically to the bottom two-thirds of the bar’s length, creating a tapered or stepped profile.
Production Capacity and Efficiency
High-Volume Output
The synchronization of these six motors resulted in extreme efficiency. The machine was capable of producing two finished end bars per second.
Assembly Throughput
In practical terms, this production rate provided enough components to assemble 60 frames per minute. This level of throughput indicates the machine was engineered for mass production environments rather than small-batch crafting.
Understanding the Trade-offs
Specialization vs. Flexibility
It is important to note that this machine was custom-built with a complex six-motor configuration.
While this design maximized speed for this specific part, such high specialization often comes at the cost of flexibility. Altering the dimensions (such as the dado width or hole placement) would likely require significant mechanical retooling or reconstruction of the machine.
Analyzing Manufacturing Capability
To understand the role of this machine in a production line, consider the following operational focuses:
- If your primary focus is Volume: This machine eliminates bottlenecks by matching the speed of assembly, producing 120 units per minute.
- If your primary focus is Precision: The automation ensures that critical dimensions—like the 3/8-inch dado depth and 3/16-inch material removal—remain consistent across thousands of units.
This apparatus serves as a prime example of how custom automation can convert a multi-step manual process into a near-instantaneous industrial operation.
Summary Table:
| Operation | Specification / Dimension | Function |
|---|---|---|
| Hole Drilling | 4 Simultaneous Holes | Prepares bar for wiring/assembly |
| Top Dado Cut | 1 1/16" Wide x 3/8" Deep | Ensures precise top bar fitment |
| Bottom Dado Cut | 5/8" Wide x 3/8" Deep | Ensures precise bottom bar fitment |
| Profile Shaping | 3/16" Material Removal | Tapers bottom 2/3 of the bar |
| Output Speed | 2 Units Per Second | Supports assembly of 60 frames/min |
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