Combined production of sawn timber and firewood billets at a birch sawmill in Finland: A simulation approach

Abstract

Growing markets for chopped firewood have created alternative uses for the by-products of sawmills. Based on empirical data and simulated results, the potential of birch (Betula pendula Roth, Betula pubescens Ehrh.) from commercial thinnings for combined industrial production of sawn timber and firewood billets was investigated. In the simulations, different sawing patterns were used for logs intended to combine production of sawn timber and billets for chopped firewood (‘sawlogs’), and for logs intended only to firewood production (‘firewood logs’). Finally, economical feasibility analysis was done concerning the differences between the sawmills’ traditional business concept and the novel concept combining sawn wood and firewood production. The bucking results for the volume yield of different timber assortments varied only slightly between the different bucking options, i.e. the combinations of timber assortments. The main differences in the volumes of timber assortments were due to the stand type where the birch trees were sampled (planted, naturally regenerated, mixed birch–spruce). In the sawing procedure, the output of sawn timber varied between 24% and 42% of the log volume in the sawlogs, depending on the log diameter class. As the volume yield of sawn timber and firewood billets was counted together in the case of sawlogs, the log consumption was c. 1.75 m³ of roundwood per 1 m³ of sawn timber and firewood billets. In the case of the firewood logs, the log consumption rate was considerably lower, only c. 1.35. The economic calculations showed that using the firewood approach in sawing may increase the net added value of products by €1.9–5.4 m^?3 of logs, depending on their diameter class. As a conclusion, parallel production of sawn timber and firewood from logs from the first and second commercial thinning of birch-dominated stands is a concept that could work as an alliance between a sawmiller and a firewood entrepreneur. The concept could be competitive compared with both traditional sawmilling and production of chopped firewood.     

Reconstruction of Pinus Sylvestris knots using measurable log features in the Swedish Pine Stem Bank

Abstract

The objective of this study was to develop a method for reconstruction of parametrically described whorls and knots from data possible to extract from industrial scanning of logs, using X-ray scanners. The method was conceived using the logs in the Swedish Pine Stem Bank as a foundation, and was based on a few predictor features extracted from these logs; namely whorl volume, distance between whorls and distance between pith and surface. These features were not measured in images but calculated from existing parameterised knots. Simulated test sawing shows that the reconstruction method results in a representative model of the knot structure in the log, when considering the grade distribution of the sawn timber produced by the simulation program. The results of this study could, for instance, be used for improved online quality predictions at sawmills. One step in this direction is to use industrial X-ray data to enlarge the amount of log data available for sawing simulation research. Future work can, therefore, focus on developing a practical application of the results presented here.     

Log sawing position optimization using computed tomography scanning

When disjoining a log, several factors affect the value of the sawn timber. There are log features, such as outer shape, knots, rot, and so on. There are also sawing parameters, such as sawing pattern, log position, and so on. If full information about log features is available, sawing parameters can be adapted in order to maximize product value in sawmills. This is soon possible, since computed tomography (CT) scanners for the sawmill industry are being realized. This study aimed at investigating how CT data can be used to choose rotational position, parallel displacement, and skew of sawlogs, to maximize the value of the sawn products. The study was made by sawing simulation of 269 CT scanned logs of Scots pine (Pinus sylvestris L.) and Norway spruce (Picea abies [L.] H. Karst.). The results showed that value recovery could be improved by 13% in average, compared to a sawing position based on log outer shape, and 21% compared to sawing logs centered and horns down. It can be concluded that a CT scanner, used in a sawline to optimize sawing parameters, has a large potential for increasing value recovery and thus profit.     

The effect of rotation speed on the power consumption and cutting accuracy of guided circular saw: Experimental measurement and analysis of saw critical and flutter speeds

ABSTRACT

This paper investigates the effect of rotation speed and vibration response of a circular saw on the sawing process of Douglas-fir wood. An idling test was conducted on a guided circular saw to determine its stable operation speeds and vibration behavior. Short-time Fourier transform analysis was performed on saw idling test data, and variation of excited frequencies of the blade as a function of rotation speed was obtained. The saw blade critical speeds and the rotation speeds that correspond to saw flutter instability were identified. Then experimental cutting tests were conducted at different cutting conditions and the effect of rotation speed and saw vibration response on cutting power consumption and sawing accuracy was investigated. The results showed that conducting a saw idling test and vibration response analysis can identify the saw critical and flutter speeds, which is essential for identifying the optimum rotation speed of circular saw. There was a significant increase in power consumption when cutting at super-critical and super-flutter speed. The effect of rotation speed on sawing accuracy is complex and nonlinear. This effect interacts with feed speed, which makes it difficult to generalize sawing accuracy versus rotation speed in the circular sawing process.     

Sawing patterns for large-diameter sugi (Cryptomeria japonica D. Don) sawlogs: Current status and future outlook

Abstract

A survey was conducted at nine sawmills in Japan to evaluate and compare the sawing of sugi (Cryptomeria japonica D. Don) logs of 30 cm and more in diameter. The purpose was fourfold: (1) to document sawing patterns appropriate to the large-diameter logs; (2) to examine the composition of wood components (structural, nonstructural, and fixtures) produced from those patterns; (3) to investigate log and product prices; and (4) to ascertain distances to the log supplier and product markets. Impetus for the study arose from a forecasted shift in the diameter distribution of plantation trees in Japan; from small and medium-sized logs to large-diameter logs. With an overabundance of large-diameter domestic logs forecasted within the next decade, the need to understand how to best utilize and effectively process the large-diameter resource is of utmost importance.     

Influence of growth stresses and material properties on distortion of sawn timber — numerical investigation

? The board distortion that occurs during the sawing and the drying process causes major problems in the utilisation of sawn timber. The distortion is highly influenced by parameters such as spiral grain angle, modulus of elasticity, shrinkage, growth stresses and sawing pattern.

? In this study a finite element simulation of log sawing and timber drying was performed to study how these parameters interact to affect board distortion. A total of 81 logs with different material combinations were simulated. From each simulated log four boards with different annual ring orientation were studied.

? The results showed that the elastic modulus, shrinkage coefficient and growth stresses had a large influence on the final bow and spring deformation. After sawing of the log into boards, the release of growth stresses was the main contributor to the bow and spring deformation. For boards with low modulus of elasticity, the bending distortion became larger than for the boards with high modulus of elasticity. The twist deformation was very small after sawing but increased significantly during drying of the boards. The results showed that spiral grain angle and the board location within the log were the main contributors to the twist deformation.

     

Determining optimal primary sawing and ripping machine settings in the wood manufacturing chain

for wood manufacturers around the world, the single biggest cost factor is known to be its raw material. Maximum volume recovery of this raw material is, therefore, of key importance for the industry. The wood products industry consists of several interrelated manufacturing steps for converting trees into logs and logs into finished lumber. Each operation usually optimises its functionality in isolation from the preceding and following operations. It is a well documented fact that the optimisation of decisions through the whole chain of operations is considerably more profitable than the optimisation of individual operations. The objective of this study was to determine the optimal machine settings for two interrelated operations, namely the sawing and ripping operations which have tradition? ally been optimised individually. A model, having two decision variables, was developed which aims to satisfy market demand at a minimal cost. The first decision was how to saw the log supply into different thicknesses by choosing specific sawing patterns. The second was to decide on a rip saw's priority value settings, which determines how the products from the primary sawing operation are ripped into products of a certain thickness and width. The techniques used to determine the machine settings included static simulation with the SIMSAW software to represent the sawing operation and mixed integer programming to model the ripping operation. A metaheuristic, namely the Population Based Incremental Learning algorithm, was used to link the simulation and mixed integer models and to determine the optimal settings for the combined process. The model's objective function was to minimise the cost of production. This cost included the raw material waste cost and the over or under production cost. The over production cost included the stock keeping costs and the under production cost was estimated as the buy?in cost of under supplied products from another wood supplier. The model performed well against current decision software available, namely the Sawmill Production Planning System package, which combines simulation and mixed integer programming techniques to maximise profit. The model added further value by modelling and determining the ripping priority settings in addition to the primary sawing patterns.     

Application of the wood properties of large-diameter Sugi (<Emphasis Type="Italic">Cryptomeria japonica</Emphasis>) logs to sorting logs and sawing patterns

The purposes of this study were to accumulate fundamental data on wood properties within large Sugi logs and to take applicable variations in wood properties into consideration for sorting logs and sawing patterns. The characteristics of basic density, moisture content, growth ring width, and microfibril angle (MFA) were measured and the relationship with log and lumber quality was examined. It was considered reasonable to estimate the lumber moisture content based on the moisture content of heartwood rather than that of whole logs, especially when producing large-sized lumber. The MFA reached a constant value before the 15th ring, and within a distance of 10 cm or less from the pith. Since the E _fr of lumber correlated with that of the log affected by MFA, it would be possible to produce lumber with a higher E _fr from the outer position of the log, based on selecting a log above the E _fr . Since the MFA would also affect the lumber warp, a sawing pattern avoiding the area around the pith or enlarging the rough sawn size when a large warp was expected could be effective in improving the lumber quality. To improve the lumber quality, not only one but also multiple wood properties must be applied to the sawing pattern.     

Using a production approach to estimate economic weights for structural attributes of Pinus radiata wood

Abstract

We modeled the technical relationships between volume of Pinus radiata D. Don structural lumber (with stiffness>8 GPa) and log attributes using a stochastic frontier approach. The production models were Cobb–Douglas and Translog, while the log attributes were small end diameter (SED), wood stiffness (STF), and largest branch (LBR); however, the effect of the latter trait was not significant (p>0.05). Economic values of log traits were represented by their values of marginal product (VMP). The coefficients for the Cobb–Douglas frontier were statistically significant and the model met most of the production theoretical properties. VMP derived from the Cobb–Douglas were 2.23 NZ$/cm for SED and 16.88 NZ$/GPa for STF. The Translog frontier coefficients were also significant (p<0.05) and VMP derived from this model were 1.67 NZ$/cm for SED and 9.15 NZ$/GPa for STF. Thus, for the analyzed production stage, changes to SED and STF were relevant for improving log value recovery above MSG8+. Technical efficiency derived from the frontiers allowed to identify and characterize the best logs to produce structural grades with stiffness of 8 GPa or higher.     

A Geographical Analysis of the Swedish Woodfuel Market

The geographical variation in Swedish woodfuel market characteristics for the district heating sector has been studied using Geographical Information Systems (GIS) and cross - sectional Tobit analysis. The results indicate that local availability and competition for woodfuels influence the woodfuel consumption at inland heating plants. The factors affecting the decision to use woodfuel at heating plants close to seaports, however, were not captured by the model, suggesting that coastal location reduces dependency on the local woodfuel market. The effects of changes in local woodfuel availability on woodfuel use by an inland heating plant are presented and discussed.     

Simulation of the yield of knot-free components from Scots pine (Pinus sylvestris L.): A comparative study of star-sawing and square-sawing

Abstract

The production of knot-free wood is important since the market demands wood without knots for reasons of both appearance and material properties. This work describes a simulation of the removal of knots from star-sawn and square-sawn timber. The efficiency of the two methods is compared in terms of the length of the knot-free components obtained and the volume yield. The simulation was based on data for trees and logs taken from the Swedish Stem Bank. These data were then used to simulate the sawmill process in a computer program called the Virtual Sawmill. Data related to the boards obtained were used in a MATLAB model simulating the cross-cutting of knots. Simulated star-sawing of logs with a top diameter exceeding 230 mm gave a mean knot-free component length of 417±321 mm, while the mean length of knot-free components for simulated square-sawing of the same logs was 298±122 mm. The volume yield of knot-free components from the two sawing patterns was 91% for star-sawing and 87% for square-sawing. For timber with cross-section dimensions of 38×75 mm², the mean length and yield of knot-free components from simulated star-sawing were 451±349 mm and 90%, respectively. In simulated square-sawing, the corresponding values were 263±197 mm and 82%, respectively. This shows that star-sawing has potential for the production of knot-free timber.     

Modelling the Number of Rings in Individual Logs of Norway Spruce

In timber production, there is a need to select the right log for a given end - product. To achieve this objective, individual tree characteristics (total height, diameter at breast height and age) and external measurements made on the log shape were combined. In this study, three possible methods are analyzed to assess the number of annual rings for a given Picea abies (L.) Karst. log using modelling. The first method consists of finding a link between the number of rings and the size, the taper and the location of the log in the tree. The second one is based on the log location in the tree and the use of an height - age growth model. The third involves the whorl location inside the log and the use of an individual height - age growth model. The three methods are compared on the basis of the amount of data required by each and error analysis.     

The use of the first industrial X-ray CT scanner increases the lumber recovery value: case study on visually strength-graded Douglas-fir timber

Key message

Industrial computed tomography scanning of logs provides detailed information on timber quality prior to sawing. A sawing simulation—considering log rotation angle and knot size accuracy—revealed an average value increase of up to 20% for the best angle compared to the conventional horns-up position.

Context

Computed tomography (CT) scanning has the potential to improve the value of products sawn from logs and meets the increasing demands of the wood industry for detailed information on log quality prior to processing.

Aims

In a validation step, automated measurements of knot cluster variable DAB (DIN 4074-1:2012-06) using CT were compared with manual measurements. In a second optimization step, the hypothesis that the value of the sawn products is increased by sawing at the best rotation angle as opposed to the horns-up position was tested.

Methods

A sample of 36 Douglas-fir logs were scanned in an industrial CT scanner, and sawn into boards. Knots on the boards were manually measured, and compared with the corresponding knots on virtual boards created from the CT data. The error of the DAB was measured by comparing CT data to manual measurements. An optimized sawing simulation was performed, using the measured DAB error to account for CT measurement errors, as well as a rotational error to account for errors in the log turning equipment. Using the results of the sawing simulation, Monte Carlo simulations were performed to show the potential and benefit of an industrial CT scanner.

Results

The three largest DABs measured by the CT showed good correlation to the measurements on the manual boards. The simulation revealed an average increase of value from 4 to 20% compared to the conventional horns-up position depending on the relative price differences between the strength grades.

Conclusion

By using a CT scanner to optimize sawing, sawmill owners can process logs in a better way to produce final products with increased added value.

     

Log sawing positioning optimization and log bucking of tropical hardwood species to increase the volume yield

The sawmill industry is a very important link in the Mozambique forest products value chain, but the industry is characterized by undeveloped processing technology and high-volume export of almost unrefined logs. The low volume yield of sawn timber has been identified as a critical gap in the technological development of the industry. To improve the profitability of the industry, there is thus a need to develop methods and techniques that improve the yield. In this paper, different positioning of logs prior to sawing and the possibility of increasing the volume yield of crooked logs by bucking the logs before sawing have been studied. A computer simulation was used to study the cant-sawing and through-and-through sawing of the logs to determine the volume yield of sawn timber from the jambirre (Millettia stuhlmannii Taub.) and umbila (Pterocarpus angolensis DC.) species. The optimal position, i.e. the position of the log before sawing that gives the highest volume yield of sawn timber for a given sawing pattern when the positioning parameters, offset, skew and rotation, are considered gave a considerable higher volume yield than the horns-down position. By bucking very crooked logs and using the horns-down positioning before sawing, the volume yield can be of the same magnitude as that obtained by optimal positioning on full-length (un-bucked) logs. The bucking reduces the crook of the logs and hence increases the volume yield of sawn timber.     

Variation in log quality and prediction of sawing yield in oak wood (Quercus robur)

Context

The commercial feasibility of sawmilling depends on the expected volume and value of sawn planks. Models that predict the volume of sawn timber of a particular quality and produced from logs of known characteristics are therefore very useful.

Aims

The objectives were to study variation in sawing yield and to obtain models that predict lumber volume and grade recovery on the basis of easy-to-measure predictor variables of saw logs.

Methods

Forty-six oak trees growing in Galicia (NW Spain) were felled and cut into logs. The logs were visually graded and sawn mainly into quartersawn planks, which were dried, planed and visually graded for structural purposes.

Results

The total volumetric sawing yield was 47.6 %. The sawing yield for planks of structural dimensions (cross-section, 70?×?120 or 70?×?170 mm) was 43.4 %, but decreased to 8.4 % for structural sized and quality grade beams because of wane and biotic damage in many pieces. Log grade did not significantly affect sawing yield in the sample analysed, despite the wide range of diameter over bark at the smallest end in the sampled logs (22–77 cm). The sawing pattern affected total sawing yield (F?=?4.913; p value?=?0.001) and the sawing yield for structural planks (F?=?6.142; p value?=?0.0002); radial sawing with one cut and live sawing of half logs provided the highest yields. Three models were proposed for estimating sawn volume in timber products, with the small-end log diameter over bark as the predictor variable and R _adj ² between 0.31 and 0.78 (p value?<?0.01).

Conclusion

For the purpose of producing oak timber destined for structural use, the presence of bark and sapwood in planks must be reduced in the sawing process; this would decrease the total lumber recovery but increase the timber value yield. Air drying must be accelerated to reduce biotic damage in sawn planks. Geometric mean diameter over bark at the smallest end (d) outperforms other measures as a predictor variable for total or structural sawn timber volume.     

Development of a monitoring system for guided circular saws: an experimental investigation

ABSTRACT

Lack of a monitoring system for guided circular saws marks one of the most critical machines in sawmills as a production bottleneck. Monitoring systems are being researched and developed for machine tools, especially for the metal cutting industry; but there are limited studies on the development of monitoring systems for circular saws in wood manufacturing process. In this study, sensors with the possibility to indicate sawing deviation were chosen that could be mounted in or on the saw guides. The sensors were: a microphone, an accelerometer, temperature sensor, an acoustic emission (AE) sensor, and a newly developed displacement sensor. A load cell was used to measure the lateral force on the guides. The outputs from these sensors were compared to the standard deviation of the board surface measured at the top of the cut. The signals from the displacement sensor, microphone, accelerometer, guide force sensor, and AE senor had no correlation to changes in the sawing deviation as measured by the standard deviation at the top of the board. Under laboratory conditions, the sound level and the AE signal did indicate the beginning and end of the cut. It was found that blade temperature is a good indicator of saw cutting performance. A newly developed temperature sensor can provide accurate temperature of the saw during cutting. The sensor can be used for measuring the rate of heating to cooling over time which can be used as a monitoring system to detect if there is any issue in the system.     

径切板生产新工艺和新设备的研究

建立了１１种径切材下锯模型，并利用图像处理及曲面拟合方法将得到的任意形状原木进行模拟锯割，结果表明，用三开法生产径切板及旋切薄木具有较高的出材率。研制了专门用于生产三开材的剖料锯机及生产工艺。在现有的带锯机前安装该剖料锯机即能利用现有锯机和跑车生产径向材。     

A review on wood machining: characterization,optimization, and monitoring of the sawing process

ABSTRACT

Sawing is the most common machining process and is present in both primary and secondary wood transformation sectors. The objective of this paper is to review how it is affected by different factors. The current challenges associated with various machining factors, process monitoring, and sensor selection were identified and explained. Consequently, four research challenges and technological gaps were outlined. (1) Contradictory results have been reported due to different cutting processes, wood species, measurement methods, and cutting speed range studied in literature, so special consideration needs to be taken when comparing results with those available in the literature. (2) Laboratory test conditions cannot yet fully represent the extreme cutting conditions in sawmills. More emphasis should be placed on those harsh industrial cutting conditions. (3) Research on wood cutting lacks multi-objective optimization approach, which suggests that sawdust generation should be simultaneously analysed with surface quality and power consumption. (4) Compared with metal cutting, little research has been conducted on wood sawing monitoring using an artificial intelligence approach, which should be prioritized in designing adaptive control systems. Combining intelligent monitoring and multi-objective optimization approaches should pave the way for controlling the sawing process so higher surface quality and cost efficient machining is achieved.     

原木形状识别机的设计

从原木外形轮廓与制材生产之间的关联性出发，探讨和研究了原木形状识别机设计的原理及设计的方法，为原木形状识别机的设计和制造提供了理论依据。     

基于Pro/E的链式原条造材机锯截机构的设计

实现自动化原木生产是提高贮木场原木生产效率和经济效益的重要措施.东北林区处于高纬度地区,常年低温寒冷,且目前我国尚未有适用于在低温户外作业的造材机,因此需要设计相关的造材机进行作业,提高东北林区木材资源的利用.主要根据贮木场的工作环境和效益,对链式原条造材机的锯截机构进行设计.通过计算及机械手册选取标准的零件,并运用Pro/E软件对锯截机构和关键零件进行建模,完成总体装配图.在建模的过程中介绍锯截机构的工作过程和各组成部分的作用.