A t raining and op timization system for log saw ing
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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.

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A T raining and OP timization System for Log SAW ing

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T O P S A W

A Training and OPtimization System for Log SAWing

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


Details of the seven red oak logs scanned


Comparison between sawmill and simulation results


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.ThicknessVolumeGradeValue (in inches) (in board feet) ($)

  • 1 4/4 6.5 1C 4.00

  • 2 5/4 12.9 FAS12.77

  • 3 6/4 17.4 1C14.09

  • 4 8/4 26.0 1C21.73

  • 5 6/4 20.0 1C16.26

  • 6 6/4 18.8 1C15.21

  • 7 5/4 14.3 FAS15.54

  • 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 sawingSawmill

  • 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


  • 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 years

Objectives:

  • Develop a $5-600,000 per unit CT log scanner

  • Refine the optimization software

  • 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


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