A T raining and OP timization System for Log SAW ing
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A A T T raining and raining and OP OP timization System for timization System for Log Log SAW SAW ing ing Sun Joseph Chang School of Renewable Natural Resources Louisiana State University Agricultural Center Baton Rouge, LA 70803
description
T O P S A W. A T raining and OP timization System for Log SAW ing. Sun Joseph Chang School of Renewable Natural Resources Louisiana State University Agricultural Center Baton Rouge, LA 70803 . Defect Identification on Cross-sectional Views. Results of Replication of Log #3. - PowerPoint PPT Presentation
Transcript of A T raining and OP timization System for Log SAW ing
A A TTraining and raining and OPOPtimization System for Log timization System for Log SAWSAWinging
Sun Joseph ChangSchool of Renewable Natural Resources
Louisiana State University Agricultural CenterBaton Rouge, LA 70803
Decay Inside a Knot
Heart Rot___________
Sap Wood______I
Heart Check____________________
Heart Wood_______________
SoundKnot
__________|
Decay__________|
Defect Identification on Cross-sectional Views
Results of Replication of Log #3Board Sawmill Results TOPSAW Results
ID Board Size BF Grade Value Board Size BF Grade Value
A1 6.25”x 12’ 6 FAS $6.34 6.3”x 12’ 6 1C $3.72
A2 10”x 12’ 10 1C $6.20 9.8”x 12’ 10 1C $6.20
A3 6.25”x 9.15’ 5 FAS $5.20 6.95”x 9.15’ 5 FAS $5.20
A4 8.25”x 12’ 8 FAS $8.32 8.4”x 12’ 12 FAS $8.32
A5 10.25”x 8’ 7 FAS $7.28 10”x 8’ 7 FAS $7.28
A6 5.25”x 12’ 5 SEL $4.00 6.2”x 12’ 6 SEL $4.80
A7 7.25”x 12’ 7 FAS $7.28 7.3”x 12’ 7 FAS $7.28
A8 6.75’x 12’ 7 F1F $6.93 7.2”x 12’ 7 F1F $6.93
A9 7.25”x12’ 7 1C $4.34 7.3”x 12’ 7 1C $4.34
Cant 7”x 6”x 12’ 42 NA $10.50 7”x 6”x 12’ 42 NA $10.50
Total $66.29 $64.57
Details of the seven red oak logs scanned
Log # Grade Large End Diameter
Small End Diameter
Length Board Feet
(Inches) (Inches) (Feet) (BF)1 1 17.50 14.13 11.75 692 1 17.50 12.75 11.92 443 1 14.25 13.75 11.92 565 2 14.00 13.00 12.67 616 2 11.62 11.00 12.42 377 2 14.75 13.88 12.25 618 2 14.88 14.13 12.25 75
Comparison between sawmill and simulation results
Comparison 1 Comparison 2 Comparison 3Simulation
Results $479.05 $497.26 $356.62 Sawmill Results $422.06 $422.06 $278.42 Percent
Gain 13.5% 17.8% 28.1%
Challenges for the Internal Defect Based Sawing Optimization System
• Hardware: A fast, more powerful, strong, durable, and low cost scanner
• Software: A fast optimization software
• With a fast solution algorithm and smart programming, a real time optimization software has been developed
Optimal Cutting Sequence• Cut No. Thickness Volume Grade Value (in inches) (in
board feet) ($)
• 1 4/4 6.5 1C 4.00• 2 5/4 12.9 FAS 12.77• 3 6/4 17.4 1C 14.09• 4 8/4 26.0 1C 21.73• 5 6/4 20.0 1C 16.26• 6 6/4 18.8 1C 15.21• 7 5/4 14.3 FAS 15.54• 8 6/4 13.4 FAS 15.31• 9 4/4 5.4 1C 3.31
» » Total Volume 134.8 BF Total Value $118.22
Results related to Log #3
• Sawmill production: $66.29• TOPSAW replication: $64.57• TOPSAW simulation: $91.32 (+ 37.8% over sawmill production)• TOPSAW optimization: $118.22 (+29.5%
over simulation, +78.3% over sawmill production)
A comparison between live sawing optimization and sawmill production • Log Live sawing Sawmill• Optimization Production• Log 1 $92.35 $84.20• Log 2 $94.97 $69.91• Log 3 $118.22 $66.29• Log 5 $100.48 $64.81• Log 6 $74.25 $32.42• Log 7 $45.23 $59.44• Log 8 $63.23 $41.81• Average Gain 40.5%
A Comparison between Live Sawing and Bi-directional Sawing Optimization
• Log Live Sawing Bi-directional Sawing• Optimization Optimization• Log 1 $92.35 $93.94• Log 2 $94.97 $107.7• Log 3 $118.22 $122.73• Log 5 $100.48 $107.9• Log 6 $74.25 $74.8• Log 7 $45.23 $53.6• Log 8 $63.23 $71.3• Average gain of bi-directional over live sawing 7.3%
Why we need TOPSAW• Log cost accounts for about 60% of the hardwood
lumber production cost based on the data of the 1997 Census of Manufactures
State Cost of Value of log cost as a % Materials Shipments of shipments
IN 119395 211461 0.56KY 221508 391409 0.57MO 148512 241356 0.62OH 154080 260451 0.59PA 432503 720675 0.60WV 255149 422082 0.60
mean= 0.59std= 0.02
• increasing log conversion efficiency, therefore, produces a significant gain in lumber revenue and mill profit
• It holds the key to the competitive advantage in the future.
Only the Paranoid survives
• Our competitors also recognize that, particularly our Canadian friends up north.
Only the Paranoid Survives
• Canadian softwood sawmills already have an edge over their U.S. counterparts.
• Despite a 27% import tariff, Canadian softwood sawmills can still undercut domestic producers in the US market.
• In terms of hardwoods, over the last 10 years, US hardwood log exports doubled and Canada’s share of the export increased from 59% to 70%. As a result, more than ever US hardwood logs are sawn into lumber in Canada.
• Forintek Canada has embarked on a sawing optimization project similar to TOPSAW to establish firmly the competitive edge for the Canadian hardwood sawmill industry.
• It is time to establish a Hardwood Sawing Technology Center, make TOPSAW a reality, and regain the competitive edge.
Hardwood Sawing Technology Center
Goal: To commercialize TOPSAW in 3-4 yearsObjectives:
1. Develop a $5-600,000 per unit CT log scanner
2. Refine the optimization software3. Develop a log set-up system to accurately
and quickly orient and position the log for sawing
• Cost over 4 years• With sawmill equipments
$3.5 million• Without sawmill equipments
$2.5 million
TOPSAW Benefits
Individual Sawmills
Sawmill Industry Nation
Increased Profit
StrengthenedGlobal
Competitiveness
Enhanced Resource
Conservation
Consumers
Improved LumberQuality
