Log Precut Patterning for Faster Sawing and Wood Recovery
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Solution Overview
Problem
Existing wood processing systems face limitations in throughput speed due to the depth of cut required by saw modules, which is often hindered by the need to cut through extraneous wood, and there is a trade-off between maximizing throughput and wood volume recovery depending on material costs and processing accuracy.
Innovation Solution
The implementation of a precut module with profilers and circular saws to reduce the depth of cut required by saw modules by removing extraneous material upstream, combined with a scanner/optimizer system to calculate optimal cut patterns that balance throughput speed and wood volume recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If saw modules cut through extraneous wood to obtain side boards, then wood volume recovery is maximized, but throughput speed decreases due to increased depth of cut
Solution Approach 1:
The cutting process is divided into multiple stages: primary breakdown with chipper and saw module, followed by secondary breakdown with edger. The profiler further segments the cant into blocks with predefined dimensions before edging, distributing the cutting workload across multiple devices rather than requiring a single deep cut through all material
Solution Approach 2:
The profiler performs preliminary action by forming blocks with predefined longitudinal sides and widths before the edging operation. This pre-shaping reduces the amount of material the edger must remove, allowing optimized cut patterns that balance throughput speed and wood volume recovery without requiring the edger to cut through excessive extraneous wood
2Productivity
If profiler forms longitudinal sides of side boards before cutting from cant, then throughput speed increases, but manufacturing precision of final dimensions decreases
Solution Approach 1:
The side board production is segmented into two distinct operations: the profiler forms blocks with preliminary longitudinal sides and widths, then the edger performs the final precision cutting to exact dimensions. This division allows each device to specialize - the profiler optimizes for speed while the edger ensures precision
Solution Approach 2:
The profiler performs preliminary action by creating blocks that are close to final dimensions but not quite precise enough. These pre-formed blocks are then fed to the edger which completes the precision work, combining the benefits of fast preliminary shaping with accurate final dimensional control
3Manufacturing precision
If edger cuts flitches longitudinally to produce side boards, then manufacturing precision is improved, but throughput speed decreases
Solution Approach 1:
The profiler performs preliminary action upstream by forming blocks with predefined longitudinal sides and widths before the edger operates. This pre-shaping reduces the workload on the edger, allowing it to maintain high precision while operating at improved throughput speeds since it doesn't need to remove as much material
Solution Approach 2:
The cutting operation is segmented so that the profiler handles the rough shaping and preliminary cutting, while the edger handles only the final precision work. This segmentation allows the edger to focus on high-precision cuts rather than removing large volumes of material, improving both precision and throughput
Data Source
AI summary
A precut module with one or more profiling heads and/or circular saws may be provided upstream of a saw module. The precut module may be used to implement a portion of a cut that would otherwise be made by the saw module, thereby reducing the depth of cut required at the saw module. In some embodiments, profiling heads may be used to profile a block that is wider than a desired side board. The block may be cut from the workpiece and sent to the edger. This may provide the same or better wood volume recovery and/or throughput speed than profiling the side board or cutting the side board from a flitch. In some embodiments, cut patterns for the precut module and other machine centers may be calculated and/or selected based on a desired depth of cut at the saw module, desired throughput speed, wood volume recovery, and/or other parameters.