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Author Topic: Automated Twin blade sawmill build.  (Read 36507 times)

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Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #20 on: November 02, 2014, 01:41:12 pm »
Work has been busy this hitch but finally getting a chance to get caught up on the design problems still left and get the parts all ordered for when i get home Nov 13th i can finish my dream project.
Current status:
1. Motor has been rotated on the motor frame and mounted on the carriage.
2. Added (2) 5/8"acme rod to move the motor frame left and right on the carriage, originally i was planning on it sliding on top of 1"angle iron turned down and the motor frame sliding on uhmw blocks, but now im thinking i may have to get a back up plan ordered.
3. The blades came in and the machine shop has finished them up and are ready for pick up.
4. The carriage will raise within the frame by (4) 1"acme rod connected with 50H chain.
5. The wheelchair motors came in but they have 17mm shafts that are not very easy to cross reference in the US, finally found (2) connectors on ebay and got them delivered.
Still left to do.
1. mount up/dn motor and connect it with sprocket and chain to the acme rods.
2. mount the side to side motor and connect it to the acme rods.
3. select the feedworks motor and mount it, the  gearbox, and cross frame shaft so that there will be a drive sprocket on each side of the frame.
4. Design the frame rails so that they can be extended.
5. Design the electrical controls so that there can be manual controls for now and a more automated functions later.
Home built automated twin blade

Offline pineywoods

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Re: Twin blade sawmill build questions.
« Reply #21 on: November 02, 2014, 03:22:01 pm »
Looking good casey. I'm anxious to see that thing making some lumber. Plan on some visitors when the sawdust starts flying. I'm only about 30 minutes from you, if I can help, just yell..
1995 Wood Mizer LT 40, Liquid cooled kawasaki,homebuilt hydraulics. Homebuilt solar dry kiln.  Woodmaster 718 planner, Kubota M4700 with homemade forks and winch, stihl  028, 029, Ms390
100k bd ft club

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #22 on: November 12, 2014, 04:55:53 am »
Last day on the rig, ready to start the trip back to America.
Got the bulk of all the parts ordered to hopefully finish the sawmill this hitch. Added a PLC and encoder feedbacks to all movements so it should be as accurate as a CNC assuming the mechanical slop is tight enough. looking forward to finally getting her put together and creating some lumber.
Home built automated twin blade

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #23 on: December 19, 2014, 09:02:12 am »
With Thanksgiving and christmas parties and raising 5 kids i didnt get to finish the mill before heading back to work but i got a lot closer. here is some pics:
Home built automated twin blade

Offline pineywoods

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Re: Twin blade sawmill build questions.
« Reply #24 on: December 19, 2014, 10:22:22 am »
Pics didn't show in the post, but I went to your gallery.  Impressive. I wanna come eyeball that rig. Will be next year before I can get loose, but you can't be more than 30 minutes from me. PM your schedule and location...
1995 Wood Mizer LT 40, Liquid cooled kawasaki,homebuilt hydraulics. Homebuilt solar dry kiln.  Woodmaster 718 planner, Kubota M4700 with homemade forks and winch, stihl  028, 029, Ms390
100k bd ft club

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #25 on: December 19, 2014, 12:48:16 pm »
Hi Piney woods, can you refresh me on how to post pics in a reply. Ive got them added into my gallery, Our internet police blocks our ability to view video but i read the help thread and tried to link my gallery to my profile but when i looked at the picture in the gallery it had a 6 digit number and when i went to my profile and tried to link the gallery it would only let me put in 5 numbers so i added the last 5. But it still doesnt work. I click "click here to add photos to post"but it takes me to my computer instead of the gallery.
Home built automated twin blade

Offline CaseyK

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Home built automated twin blade

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #27 on: December 19, 2014, 12:57:49 pm »
 

 

 

  



  




 
Home built automated twin blade

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #28 on: December 19, 2014, 01:03:03 pm »
The first pic above is for raising and lowering the saw frame up and down. Used 50H chain and 1"acme rods on all 4 corners.

Second pic  shows the poor man clutch, over center toggle  idle wheel tension adjuster.

Third pic shows the 26"vertical saw and to the right the 21"horizontal saw blade.

Forth Pic shows a front view of the sawmill as looking from the log. I was able to get it up on the rails just a few hours before leaving to go back offshore.

Home built automated twin blade

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #29 on: December 19, 2014, 01:16:17 pm »
I was able to run the carriage left and right and the saw frame up and down by using relays and switches giving me a low speed and high speed (12v / 24v). Now that im offshore im starting to work on the PLC program and wiring schematics and do it such a way so that if the plc has problems i wont loose any of the manual functionality but with the flip of a switch have a full range of automated movements and functions depending on if i want to cut dimensional lumber or 1xs and be able to plain saw or quarter saw with or without multiple cants. That along with all the safety interlocks and options looks like it is going to be really neat program to write and debug.
Oh and yes i am going to make some guards for the blades before anyone picks on me about it.
I get home January 8th so my goal is to have it set up in place and cutting manually by mid January.
Home built automated twin blade

Offline WmFritz

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Re: Twin blade sawmill build questions.
« Reply #30 on: December 19, 2014, 06:42:03 pm »
Awesome build. I look forward to see it up and running.
~Bill

2012 Homebuilt Bandmill
1959 Detroit built Ferguson TO35

Offline Swatson

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Re: Twin blade sawmill build questions.
« Reply #31 on: December 19, 2014, 06:56:46 pm »
Now that is interesting.  That would make dimensional lumber really fast.  Do you still have the capacity to cut wider boards ( 2x the blade cut depth) with it?
I cant figure out which one I like better: working with wood or making the tools to work with wood.

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #32 on: December 20, 2014, 03:39:48 am »
Swatson, due to being a twin blade im not going to be able to 2x horizontal blade cuts but there is a rumor that a slabber attachment and/or a band mill at the other end of the 40ft track may be my next project once this one is operational.
Home built automated twin blade

Offline CaseyK

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Re: Twin blade sawmill build questions.
« Reply #33 on: January 03, 2015, 02:15:58 pm »
Still on the rig for another 5 days but my UPS delivery man is going to be wearing my driveway out between now and then. I got the bulk of all the remaining items ordered over the past 2 days:

encoder adapters, encoder flex couplings, additional photo eyes and associated cables and mounting brackets, PLC rack, PLC I/o cards, PLC motion control cards, battery disconnect switch, junction boxes, back plane for main electrical panel, Touch screen operator panel, PLC software, graphics software, estop cable pulls, extra bearings, extra acme nuts for reworking the carriage left / right fine tune adjustment, laser level, emergency fuel and air shut off solenoids,  ect.

Finalized how I was going to wire everything up interfacing the wireless remote and PLC in case the PLC or Operator develops a problem I can flip one switch and run manually. Just got to draw it up pretty for when I start laying out my panel.

Have dumped probably 20 Hours into programming the automatic log cut optimization program & Its coming along nicely. Just about when I think im done I think of another option I would like to add. So far it can:

Scan the log and automatically measure length and diameters at each end, consider if you want to reject a bad core section out of the solution, consider if you have selected  that you want a certain number of certain sized cants, then consider if you want max width, primary selection, or secondary width boards and then primary and secondary thick boards. Then you can select it you want the entire log to be cut plain sawed or quarter sawn. Then it will crunch the numbers and show you 2-3 options and total up the number of boards of each size and the % of boards that will be quarter sawn compared to rift sawn and see which option you would like to cut.

That may sound real simple at first but when you add center core rejection, cant selection, multiple boards sizes option, and then the quarter saw option it gets a little complicated to say the least since it will have to calculate the exact (x,y) location for every board and the sequence it will occur before ever starting the first cut.

After reviewing tons of the old post of what could happen I have added some unique safeties into the mill that can initiate an all stop and shut down the diesel engines air and fuel and kill power to all motors and outputs.

Now im just ready to get home and get her set in place, leveled and plummed, wired, programmed, debugged, and started up. Im going to try plain sawing first to tune out the blade alignments but im really looking forward to being to Quarter saw an entire log without ever turning the log and minimize the waste cuts.

Once she is up and running I can work on the bells and whistles part of the plc and the operator interface.
Home built automated twin blade

Offline CaseyK

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Re: Automated Twin blade sawmill build.
« Reply #34 on: January 06, 2015, 06:19:30 pm »
Last night on the rig and I got some more stuff ordered today to complete the feed works gear ratios.

The speed will be variable with a top speed of 6.5" per second. I am thinking this will be a nice starting point but I ordered a few spare sprockets to adjust it up and down if I need to.

Tomorrow will consist of waking up at 1AM Louisiana time on the rig, catching a chopper, getting visa processed, 4 hr car drive, 7hr wait at airport , 16hrs of flights and layover to make it back home for lunch Thursday. Then get home to start opening boxes and see what all is still left to be delivered & start welding and finishing her up.
Home built automated twin blade

Offline Tom_Averwater

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Re: Automated Twin blade sawmill build.
« Reply #35 on: January 07, 2015, 04:31:30 am »
Just curious,  where is the rig at you are working on ?
He who dies with the most toys wins .

Offline CaseyK

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Re: Automated Twin blade sawmill build.
« Reply #36 on: January 07, 2015, 04:38:08 am »
Im in the Atlantic 150 miles south of Rio De Janeiro, Brasil. Been working down here for 5 years, 28/28, as a electronics tech. Before that I was a field engineer 12 years with Rockwell Automation specializing in PLC, drives, and safety systems.
Home built automated twin blade

Offline Jemclimber

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Re: Automated Twin blade sawmill build.
« Reply #37 on: January 07, 2015, 07:51:38 am »
Thanks for taking the time to take us along this build. It's great that you have your 5 year old son helping you out to teach him.   
 
Do you feel the 2 belt powerband (that's what it appears to be, Im not sure of the proper terminology) is sufficient to transfer the 35hp. The reason I ask is I have a 37hp wisconsin on a chipper that I'm contemplating adapting to over center similar to what you have done but it came with 4 belt pulleys coming off the clutch. The clutch was for the smaller engine and the 37hp engine I believe was too much for the clutch to handle and it burned up as well.
lt15

Offline CaseyK

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Re: Automated Twin blade sawmill build.
« Reply #38 on: January 17, 2015, 04:17:24 pm »
Finally getting a few free days to work on the mill. When balancing the saw carriage frame that moves up and down discovered there was too much sag in the frame when the motor was in the middle so we added channel bracing and then had to cut the vertical side of the angle iron and through the new brace to raise up the middle and Reweld but the fix worked perfectly, with less than 1/16" deflection now in the middle. Added the battery box, reworked the side to side acme rod connections to the saw carriage, added the feed works sprockets, changed 12v alternator to a 24 volt alternator, and am now cutting out the saw carriage safety brackets to prevent possible lifting of the engine /blades carriage. Pics to follow Sunday or monday
Home built automated twin blade

Offline CaseyK

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Re: Automated Twin blade sawmill build.
« Reply #39 on: January 18, 2015, 11:16:42 pm »
 

  

  

  

  

  

  

 
Home built automated twin blade