Truss Member Nesting Optimization for Lumber Waste Reduction
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Solution Overview
Problem
The truss manufacturing industry faces significant lumber waste due to inefficient cutting processes, despite existing optimization methods, and there is a need for further improvement in optimizing lumber use in linear feed saw systems.
Innovation Solution
A computer-based method that selects and orients truss members for cutting by comparing angles and using supplementary or close-fitting angles to nest members, allowing for optimal cutting configurations that minimize waste through rotation and orientation of truss members around their longitudinal and lateral axes, and making separation cuts when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional cutting methods are used, then the cutting process is simple, but lumber waste is significant
Solution Approach 1:
The system performs preliminary calculations and optimizations before the actual cutting process. The computer calculates optimal cutting patterns, member orientations, and nesting arrangements in advance, allowing the saw to follow pre-determined efficient paths without real-time complex decision-making
Solution Approach 2:
The patent replaces manual layout and measurement methods with a computer-based calculation system. The computer automatically determines optimal cutting patterns by processing member lists and calculating nesting arrangements, substituting mechanical trial-and-error methods with computational optimization
2Productivity
If members are cut individually without nesting, then the cutting process is straightforward, but lumber utilization is inefficient
Solution Approach 1:
The system implements nesting by arranging truss members to overlap and share cut lines efficiently. Members are positioned so that cuts for one member serve multiple members simultaneously, with the computer calculating optimal nesting patterns that maximize lumber utilization while accounting for member angles and dimensions
Solution Approach 2:
The system dynamically adjusts member orientations and nesting arrangements based on the specific list of truss members to be cut. The computer calculates optimal configurations for each unique set of members, allowing the cutting pattern to adapt to varying member dimensions, angles, and requirements
3Loss of substance
If supplementary angle nesting is implemented, then waste is reduced, but the selection and orientation process becomes more complex
Solution Approach 1:
The patent replaces manual angle measurement and comparison with computer-based calculations. The system automatically processes member angle data, identifies supplementary angle relationships, and determines optimal nesting configurations through computational algorithms rather than physical measurement and trial-and-error
Data Source
AI summary
A computer-based method for maximizing the use of lumber in the production of truss members for a truss assembly using a linear feed saw apparatus. The method comprises storing a list of truss members to be cut by the linear feed saw apparatus, selecting from the list a first truss member for cutting, the first member having a trailing end. A second truss member from the list is selected for cutting, the second member having a first end that will nest with the trailing end of the first member. The second member is oriented such that its first end nests with the trailing end of the first member. The members are then cut using the linear feed saw. The nesting members can abut across the entire member width, only across a portion of the member width or at a single point. The nested ends of the first and second members may be bevel cuts. The selecting of a second truss member may comprise comparing the angles of the cuts to be made on the trailing end of the first member to the angles of the cuts to be made on the ends of at least two of the members on the list. The selected member may have an angle to be cut which is supplementary to one of the angles of the trailing end of the first member or which is close fitting with an angle on the trailing end of the first member. The selected member is oriented such that the supplementary or close fitting angle of the selected member is adjacent the corresponding supplementary or close fitting angle of the first member. Orienting the selected member may further comprise rotating the member around its longitudinal axis, its lateral axis or both.