Millwide Insider 4-2013 by USNR

THE MAGAZINE FROM USNR | ISSUE 4-2013

TWO THUMBS UP FOR GRADING WITH THG

COMPARISON SHOPPING – WHY THG?

CLOSING THE GAP WITH MILLTRAK 3D

Contents

Millwide Insider ISSUE 4 - 2013 SUBSCRIPTIONS Tel.: 250.833.3028

A TIME FOR FIRSTS As technology pushes the limits on wood processing, USNR is for tunate to have customers that are eager to embrace each new concept as it becomes ready for prime time. In this issue we relate experiences from two recent new product debuts at two stellar customer mills. These first production installations are proving out the concepts that will move these operations forward.

Swanson Group’s dimension lumber mill at Glendale, Oregon recently installed the first production Transverse High Grader. Though the mill’s green Douglas Fir is a challenging species for automated grading, the THG is taking it in stride as the mill has since successfully passed three grade inspections.

subscriptions@usnr.com EDITOR Colleen Schonheiter colleen.schonheiter@usnr.com CONTRIBUTING EDITOR Sonia Perrine sonia.perrine@usnr.com

USNR PARTS & SERVICE 7/24 Service: 800.BUY.USNR Tel.: 360.225.8267 Fax: 360.225.7146 Mon. - Fri. 5:00 am - 5:00 pm PT www.usnr.com

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We invite you to compare the features of USNR’s Transverse High Grader with other transverse automated grading systems on the market. We think you’ll agree that the elegant simplicity of the THG is the best transverse match for today’s high speed mills.

USNR’s MillTrak™ 3D is closing the gap on logs that are fed to the double length infeed at Collum’s Lumber, Allendale, South Carolina. This technology solution was the answer to the gapping and throughput issues the mill faced.

USNR LOCATIONS Woodland, WA Headquar ters 360.225.8267 Parksville, BC

Eugene, OR

250.954.1566

541.485.7127

Plessisville, QC

Jacksonville, FL

819.362.8768

904.354.2301

Salmon Arm, BC

Painesville, OH

250.832.7116

440.352.9381

Finally, we review USNR’s presence at the SFPA Expo that took place in Atlanta, Georgia in June. One of the highlights was the introduction of another new product – our all-electric lug loader dubbed ElectraTong. It has been causing quite a stir both during and since the show, with many customers expressing interest. Enjoy the review!

1981 Schurman Way, Woodland, WA 98674. Canada Post: Return Undeliverable Canadian Addresses to: USNR c/o Colleen Schonheiter, 3550 - 45th Street Southeast, Salmon Arm, BC V1E 4N2

Swanson Group

Two thumbs up FIRST PRODUCTION TRANSVERSE HIGH GRADER IS A WINNER! USNR's Transverse High Grader (THG) made its debut recently grading the very challenging green Douglas Fir at a dimension lumber mill in Oregon. Early indications are that this new grading line is meeting or exceeding the mill's targets for achieving consistent grade out, as well as improving throughput and the mill's for tunes.

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SWANSON GROUP – TWO THUMBS UP FOR THG Strong lumber markets, an obsolete grader assist scanner and the need for fencing accuracy created the per fect storm for Swanson Group to invest in a fully automated grading line at its Glendale, Oregon dimension mill. The company chose USNR’s THG system, along with key ancillary equipment that together are improving the production and grade out for the operation. Swanson Group is a privately held forest products company that has been owned and operated by the Swanson family since 1951. The company operates four Oregon wood processing plants; a stud mill at Roseburg, the dimension lumber mill at Glendale, and two plywood and veneer plants at Glendale and Springfield. The Glendale dimension mill processes green Douglas Fir in 2x4 through 2x10, and 6’ to 20’ lengths that are marketed domestically. The recent major recession forced the company to look to new products and global markets to ensure its continued success. In addition to standard dimension products the mill also now produces rail ties and small timbers. The Glendale mill is in the midst of installing dry kilns and boilers to allow it to add dry Hem Fir to its product mix.

Selecting a system Doug Knous, corporate project manager for the Swanson operations, manages all of the major capital investments. He explained the reasoning behind the investment in the THG line. “We had an outdated geometric graderassist system and were still operating with four graders. We were targeting getting the grade out consistently day-in and day-out, as well we wanted to speed up the system and increase production.” Doug said they reviewed all of the major automated grading systems on the market and quickly narrowed it down to two competing transverse systems. “We sent packs of lumber to be tested by both systems. In the end we chose the THG based on the software, the hardware and how well the system functioned.” He went on to say that they had also considered USNR’s Lineal High Grader (LHG) system, but the transverse THG was a better fit for the mill layout.

The bottom row of sensors is visible at the THG outfeed.

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We chose the THG based on the software, the hardware and how well the system functioned.

Along with the THG the Glendale mill updated its trimmer infeed area with a USNR Revolver Lug Loader, MillTrak™ lumber flow management system, Grade Projector, TrueRead grade mark reader, Multi-Track Fence, and WinTally™ sorter management system. The PLC system for the line was updated from PLC5 to ControlLogix.

Window of oppor tunity Doug explained that the major hurdle the mill faced with the project was a hot

market, making the window of opportunity very short to shut down the line for the installation. “We had 11 days to rip the equipment out from landing table through the trim saws and install new hardware, transfers, THG system, Revolver Lug Loader, new landing table, etc. We worked 24 hours a day mechanically and 12 hours a day on the electrical side to get everything wired up. After install we still had the task of starting up the control and optimization systems and getting them tuned in.” Doug said the timing was absolutely challenging but the mill started producing on the scheduled production date. He commented that it was a very good start up.

Speaking from experience Today the Glendale operation has reduced its grading contingent from four manual graders down to one check grader. Doug speaks from experience when he says he is pleased and impressed with the performance of the THG. “I’ve dealt with some other automated grading systems and they have taken quite some time to get things tuned in to a comfortable level. Above and below grade are very important to us and those tend to be finicky and take some time to get tuned in, especially with the product mix in dimension mills. This system started up on time, and we started seeing the grade out numbers consistently filter into the percentages that we wanted. We also started to see our production numbers increase within a short time of start-up. We were pretty impressed with that.” He continued to explain that the grade out is equally as good or better than it was with the manual system, but more consistent

This system started up on time, and we started seeing the grade out numbers consistently filter into the percentages that we wanted. We were pretty impressed with that.

and with increased production. Though the performance tests haven’t yet been done he is confident the THG is ready. “We’ve passed three inspections by the grading bureau (Western Wood Processors Association – WWPA) and we’re seeing all of our grade out percentages tracking nicely to our projected targets.” Doug is convinced that as the software continues to progress and the mill gets better at tuning for its products, the system will continue to improve the mill’s fortunes.

THE IMPORTANCE OF PITH

How the system works The new USNR equipment supply begins with the MillTrak camera controlling the backlog to the Revolver Lug Loader. Once in lugs the boards are transported on a narrow, flat transfer through the THG scan frame where they are scanned for the mill’s specified defects. The THG’s belted scanner transfer is a key advantage over competitive transverse systems that require elevation changes and tend to obscure the boards during scanning. The THG scanner transfer is a simple, flat transport system that completely stabilizes the boards on thin belts that carry the boards through the scan zone. These thin belts ensure the BioLuma 2900LVG+ sensors see as much of the four surfaces of the board as possible. The THG scanner is fitted with two rows of sensors positioned off-axis both above and below the transfer; in this way all four surfaces of the board can be scanned utilizing only two rows of sensors. As well, the THG utilizes an end grain scanner positioned at lumber line that scans the end of each board, and provides the THG’s GrainMap™ technology with measurement data to identify the pith location relative to the board for highly accurate knot sizing capability. (See sidebar at right.)

Harry Ogloff, USNR’s product manager for automated planer grading systems, explains the importance of the THG’s proprietary end grain scanner in determining accurate knot sizing. “The purpose of the end grain scanner is to measure the grain at the end of the board to determine which part of the log the board originated from. Knowing the part of the log the board came from is critical to accurately determining how the surface knots are connected within the material. The end grain scanner along with other attributes of the material allows the THG to not only view the knots from the material surfaces, but also know how these knots are interconnected inside the material.” He went on to say that one key attribute for structural grading is the amount of knotty material that exists in a given cross section of the board. In a log, the knots typically will converge toward the pith (center of the log). To determine the volume of knotty material in a board and assess its structural properties it is essential to know how the surface knots connect inside the board. The end grain scanner provides important data to assist the optimizer in that determination.

The THG software classifies the defects on each board and assigns it a grade based on the size and location of the defects together with the mill’s grade definition inputs. The check grader and Grade Projector are located immediately downstream from the THG scan frame. As the boards exit the scanner the grade and trim solutions are projected onto the surface of the board for the check grader to view; he can either

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SWANSON GROUP â&#x20AC;&#x201C; TWO THUMBS UP FOR THG

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1. The Grade Projector is located immediately downstream from the THG with projectors mounted above the flow. 2. The grade and cut/trim solutions (see boxes) are projected onto the surface of the board. 3. The check grader can either agree with or change the THG's solution by making a mark on the board. 4. The True-Read grade mark reader reads any marks the check grader makes on the boards and relays them back to the optimization computer. The system then directs the PLC to adjust the MultiTrack Fence paddle positions and the trimmer's saws accordingly.

agree with the THG’s solution by letting the board pass, or override it by making a mark on the board. The True-Read grade mark reader reads any marks the check grader has made and feeds them back to the THG optimizer. The system transmits the final solution to the PLC to direct the Multi-Track Fence to adjust the paddles to position the board, and to direct the trimmer to lower the appropriate trim saws for the cut. One hurdle that the USNR engineering teams faced with the Glendale THG unit was grading for green Doug Fir. This is a very challenging species for scanning. The knots tend to be similar in color to the rest of the wood, making them difficult to detect through visual means. “Wet” wood is also challenging as the moisture content in the wood can deflect the laser and vision scans to a degree, distorting the data. That being said, the Glendale unit has overcome these challenges based on the excellent results the mill is achieving.

We've passed three inspections by the grading bureau and we're seeing all of our grade out percentages tracking nicely to our projected targets.

fussy timing and maintenance. “With this fence we put it in, set it up and it has been smooth and problem free from start up.” He said his experience with the Revolver Lug Loader was similar; it went in easily and is running far better than others the mill has previously used. He mentioned that the MillTrak camera is working to minimize crooked boards being fed to the lug loader. He said, “The front end of the line is running very well and that is a big piece of the production increase we’re seeing.” The mill also installed USNR’s WinTally sorter management solution. One of the key strengths afforded this line is the information feedback loop capability when combining the THG automated grading system controlling the trimming process, with the WinTally system managing the sorting process. This combination offers a very powerful tool for managing product processing and package makeup. Doug commented, “We do some unique things with our lumber packs, and we also produce some premium grade, no-wane product. The system allows us to select how we want to pull that specialty grade from our products and package it. We are utilizing that capability today on a couple of items and we have plans to take that a bit further down the road. We have a lot of future potential things that we want to implement, we are just not at that stage of the project yet.”

Training Strengths of this line Doug was complimentary about the ancillary equipment that was installed with the project. “The Grade Projector is a pretty valuable piece of the check grading system. The graders can see the projected grade, agree or disagree with it and make changes if they so desire.” He was particularly impressed with the Multi-Track Fence, commenting, “The fence is an outstanding system. It’s very smooth and precise and its operation has been flawless.” He went on to explain that paddle fences typically pose problems such as an abundance of moving parts that require

Training is an essential element of any new process. It ensures the mill receives the best possible return on its capital investment. Training for Glendale personnel was implemented through a variety of means. The mill sent packs of lumber to USNR’s Eugene, Oregon facility for testing

on the THG during the evaluation phase of the decision making process. Glendale personnel were on hand once the purchase decision had been made, and received both theoretical (classroom) training as well as hands-on training on the Glendale unit while it was at the Eugene facility. Once installed at the mill, Glendale personnel were intimately involved in the THG start-up phase and tuning process.

Looking ahead Doug is optimistic about the future direction of the Glendale mill with the new THG line, and with the added implementation of lumber drying capability. “Right now with the dry kilns coming on and the THG line in place, it will allow some more products as far as species go as well as dry vs. green products. With the THG, early indications are that consistency is better and we are very close to meeting or exceeding our grade out goals. We are pretty excited that not only are we close to meeting our targets but we will be able to surpass them going forward. We are consistently running more production through the system. We’ve increased speed about 10% and that is now limited by other equipment.” Doug also commented that the Glendale operation will have its dry kilns running by the end of 2013, and by 2014 the company expects it will be producing some different products for the marketplace to allow it to be more versatile with its product mix.

Video of the THG line at the Glendale mill: http://vimeo.com/ 70978545

The system allows us to select how we want to pull that specialty grade from our products and package it.

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THG Differentiators

Comparison shopping

DISCOVER HOW THG STACKS UP AGAINST THE COMPETITION We want to make it easy for customers to determine which attributes weâ&#x20AC;&#x2122;ve built into THG that set it apart from the competition. Here are ten key elements you need to consider when evaluating an automated grading system for your mill. USNRâ&#x20AC;&#x2122;s engineers have spent countless hours developing a transverse automated grading solution that would provide the equivalent world-class per formance to our proven Lineal High Grader (LHG). We were not satisfied until it offered the most potent combination of features for the highest level of achievement of any automated lumber grading system on the planet.

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THG utilizes the same time-tested technology derived from the LHG’s image analysis and optimization software. The THG’s user interface shown above depicts knots outlined in green, splits and shake with purple, and wane outlined with red.

Proven software defect analysis and classification

Experience THG is backed by over 20 years of experience with scanning for grade in wood. It utilizes many of the same scanning technologies and software algorithms as USNR’s complete family of automated grading systems – for green lumber in the sawmill, dry lumber in the planer mill, and for chop and rip applications in secondary wood processing operations.

technologies the classification of knots is far less reliable. DataFusion offers a level of peace-of-mind that you won’t find in other automated grading systems.

USNR’s THG offers the industry the same high value and recovery performance that is proven the world over in the LHG. The THG utilizes the time-tested technology derived from the LHG’s image analysis and optimization software and combines it in a transverse package. If results are what you are looking for, you can be sure that is what you’ll get with a software system that is proven to produce results in demanding mill environments around the world.

BioLuma 2900LVG+ scanning system The THG utilizes the industry’s most advanced scanning system. BioLuma 2900LVG+ sensors integrate GrainMap technology, XHD color vision and HD laser profiles. They collect ultra-high resolution images and precise geometric and grain angle measurements along the entire four surfaces of the boards − the highest resolution and fastest sampling rate of any transverse sensor available today.

DataFusion™ USNR pioneered the DataFusion concept in the LHG. With DataFusion, all of the data collected from scanning – laser profile data, color vision imagery and GrainMap laser mapping – is correlated and verified from one technology to another to ensure the accuracy and reliability of the data. For example, knots require both vision and laser measurement technologies. The vision data gives clues based on the variation in the color of the wood. GrainMap laser mapping measures the deviation of the grain that occurs around a knot. Without the collaboration of data using both of these

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THG DIFFERENTIATORS – COMPARISON SHOPPING

End grain scanner The THG utilizes an end grain scanner positioned at the lumber line that scans the end of each board. It provides the THG with information about which part of the log the board originated from, allowing the THG to determine the location of the pith relative to the board. The ability to determine pith location ensures much more accurate knot sizing than any system that lacks this capability.

Planer

The end grain scanner assists the THG to determine the size and shape of knots, and their connectivity within the board. The 3D illustration below shows the THG’s model of the inside of a board; knots are depicted in purple, laser dots in green, and the log’s pith (red, yellow) which is located outside of this board. The THG is able to measure the shape of the knots and their volume displacement of wood inside the board, which affects the board’s grade. Note that the knots converge toward the pith. The image above shows laser dots arrayed on two surfaces of the board from the top and bottom rows of BioLuma 2900LVG+ sensors. Also note the narrow belts (approximately 1” wide) that transport the boards through the scan zone.

Full 4-face scanning with 2 rows of sensors USNR’s integrated, multi-technology scanning system (BioLuma sensors) allows the sensors to be turned off-axis, and scan two faces of the board with each row of sensors. This configuration accomplishes full four-face scanning with only two rows of sensors. This is one of the key attributes of a simple design, making the scanning system easier to calibrate and easier to maintain.

This 3D illustration shows the THG’s model of the inside of a board; knots are depicted in purple, laser dots in green, and the log’s pith (red, yellow) which is located outside of this board.

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The illustration at the top of pages 8 and 9 shows an elevation view of the off-axis placement of sensors and lighting with respect to the flow of boards. The image above shows the laser dots arrayed on two surfaces of a board from top and bottom rows of sensors as it moves through the scan zone.

TYPICAL THG LAYOUT CONFIGURATION

Fence Grade mark reader Check grader Trimmer

THG

Lug loader Grade Projector display zone

Flat transpor t

LED illumination Lighting is of utmost importance for any visual scanning system. Light must be spread evenly across the scan zone and devoid of any hot spots that require shielding. It must cover all 4 faces of the piece evenly and consistently, and it must be as white as possible to accurately image the colors of the board. It must also be reliable and not degrade over time. It should be simple to maintain and calibrate, and easily accessible to keep clean. USNR chose its LED lighting system for THG to meet all of these criteria. LED is a long functioning light source that is clean, stable and easy to maintain. THG is configured with four separate light bars to ensure even coverage over each face of the board, and is positioned off-axis for highlighting cracks and splits. Unlike other light sources such as halogen, LEDs don’t degrade over time and run relatively cool for reduced fire hazard.

Simpler is better. USNR’s THG utilizes a short, flat transport system to move boards through the scan zone. THG’s simple, level transport system is designed to accommodate the highest piece rates. In most mill layouts this configuration can easily be dropped into the existing flow for minimal disruption and minimal downtime (see layout above). THG’s transport system also features the narrowest of belts (pictured opposite page) to transport the boards through the scan zone, ensuring minimal obscuration of the bottom surface of the board. The sensors see as much of the bottom of the board, and the defects, as is possible with a transverse scanning system. This simple, well designed transport system means reduced capital cost and reduced requirement for ongoing maintenance that more complex transport systems demand.

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THG DIFFERENTIATORS – COMPARISON SHOPPING Following are a few key features that THG customers can access when it is combined with a WinTally system.

Projectors

Reduced product setup: enter products ONLY once at the WinTally computer Increased product control for enhanced product mixing Built-in board logging from the optimizer

Grade Mark Reader

WinTally automatically saves selected board images for diagnostics Bin dispersion allows the tally to disperse products throughout a bin Product mixing allows a mix of products within a bin

Grade Projector USNR’s new Grade Projector system is an innovative way to display lumber grades on boards. The system uses a projector mounted above the flow to project the grade determined by the optimizer directly onto each board, and tracks that projection with the board as it passes by a check grader (pictured above). Boards are not marked in any way, so your freshly planed lumber remains clean and bright. The Grade Projector does the job easier and better. Projected symbols are customizable; you can create symbols your facility is used to using All saw lines including near end, far end and cut-in-2 are projected onto the material in their respective locations making it very easy to view trim decisions Multiple grades can be projected onto boards for multi-grade cut-in-2 decisions Projections are highly accurate and can track material on smooth or lugged chain Projections detect skewed material and adjust appropriately User-selected defects can be highlighted for the check grader to pay special attention to specific board solutions

WinTally integration Integration between the THG and WinTally sorter management system is a powerful combination that offers a wide variety of lumber processing, sorting and packaging options not available with other suppliers’ solutions. When WinTally is integrated with the THG (or LHG) the mill enters the products and quantities it wishes to make into the WinTally computer. The optimizer’s board solution is automatically relayed to the WinTally system for sorting the boards into the appropriate bins in the quantity that is called for. Further, if a mill is cutting to order once the order is filled the optimizer no longer makes that product. Instead it will select the next most valuable product per the mill’s inputs. This could be a cut-n-two or single board solution depending on the value of currently active products and the physical characteristics of the piece. The mill can specify the parameters of any package. For example, it may choose to pull a mixed product package for a special customer, and create the package with an even dispersion of a particular product within the pack. The options are limited only by the mill’s imagination and its customers’ desires.

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Jag pack management minimizes the number of unfinished bins (jags) remaining at the end of a shift by shutting off products at the optimizer once those bins are filled; remaining boards are reoptimized for a different grade or length Sort-to-order capabilities; any number of products can be sorted for specified packages Flexible sort setups for each product run; new products can be added at any time Trim-by-product allows a product that does not appear in the active product list to be trimmed to an allowable product Virtual bin directs multiple sorts to any specified location USNR developed our THG after much careful thought and attention to the needs of customers just like you. If you are considering an automated grading system please contact us to find out how our experience, our technology and our commitment to your needs will be the perfect match for your mill.

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Collum's Lumber

Closing the gap A NEW INNOVATION LEADS TO IMPROVED PIECE RATES USNR builds on its solid base of technology and experience with the launch of a new method to control the flow of logs at the primary breakdown end. In this application MillTrakâ&#x201E;˘ 3D uses advanced technology to maximize the efficiency of loading logs into a conveyor. This new system is proving its worth with dramatically increased throughput for this first installation. 14

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3 1

1. Log 1 is loaded on the infeed belt following its predecessor. 2. Log 2 is queued up on the last step of the step feeder, awaiting its turn. 3. Log 2 is loaded on the infeed belt while Log 3 is advanced up the step feeder.

The folks at Collum’s Lumber don’t pull any punches when it comes to applying new technology. When faced with a bottleneck at the mill’s primary line that couldn’t be fixed through trial and error, the obvious next step was to look to technology for the solution. And though the solution existed, MillTrak™ 3D for log gap control hadn’t yet been proven out. Small matter when a relatively limited investment could reap a major improvement in throughput. Today that investment in the MillTrak 3D solution has proven itself with big returns, and the sky is the limit for this stellar operation. Collum’s Lumber is a thriving family owned, proudly independent operation located at Allendale, South Carolina. The mill’s roots date back to the 1930’s, started by U.W. Collum at Batesburg, SC and later moved to its current location.

The company is owned and operated by three brothers; Micky, Bill and Hank Scott are fourth generation descendants of the founder. The Allendale site comprises a sawmill, planer mill, dry kilns, pole mill, reman facility and treating plant. Its

Southern Yellow Pine products include dimension lumber, treated wood products, poles, chips, biomass and remanufactured components. The mill’s capacity is in the range of 150 mmbf annually.

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COLLUM'S LUMBER – CLOSING THE GAP Over the years the mill has seen several major upgrades, including building a brand new sawmill in 2002 with state-ofthe-art equipment and processes, with a double length infeed (DLI) line and curve sawing gang system from USNR’s Salmon Arm, BC division. In 2006 it installed a new log merchandizing line with debarker, and a new log crane in the last year. More recently it installed USNR’s smart tipple at the Trimmer outfeed, Multi-Track Fence and in June the MillTrak 3D log gap control system on the DLI line. The DLI line processes logs up to 28” diameter in 8’ to 16’ lengths, with larger logs – up to 35”, being fed to the mill’s carriage line.

Problems and solutions Gregg Hutto is the sawmill manager and has been with Collum’s Lumber for 21 years. He explained why the mill chose to upgrade the primary line with the MillTrak 3D system. “We wanted to speed up the DLI and so we needed to control the log gap.” He went on to say that the mill had been using a series of photo-eyes with some operator intervention to advance the logs through the step feeder to the DLI infeed. The biggest problem with that

We wanted to speed up the DLI and so we needed to control the log gap.

system was that DLI throughput was very inconsistent, particularly with their mixed range of log diameters and lengths all being fed in the same shift. “The operator tried manual log gapping. If he got them too close together the photo-eyes would override and stop the system to spread the logs apart. We could never close that gap downstream. We sped the gang saw up, and then the DLI wasn’t running fast enough to keep up.” Gregg knew there had to be a better solution to improve feeding of the DLI and increase overall production at the sawmill. Bob Tweedy, USNR’s regional sales manager, was at the mill when Gregg asked him about a solution to this problem. Bob told him about the capabilities of the MillTrak 3D system. USNR has many MillTrak 2D systems operating in the field

monitoring the flow of lumber in a variety of mill applications. The basic concept was tried and true but had yet to be proven in a 3D log gapping system. That didn’t deter Gregg. He said, “I chose MillTrak because of the support we get from USNR, and the simplicity of the MillTrak system.” Gregg did have one concern about the amount of vibration at the step feeder area and wondered if it would cause any issues. “We thought we would have a problem with vibration around the step feeder, but as of yet we are having no problems. MillTrak seems to me to be very versatile and can withstand problems such as vibration.”

A better method USNR’s MillTrak 3D system is designed to maximize the efficiency of loading logs into a conveyor during primary breakdown processing. While the old system at Collum’s Lumber would reference a photo-eye located downstream, the log had to travel an extended distance before the system would feed the next log. This resulted in a rather large gap, and that gap would vary based on log length and the current speed of the line.

Two sensors are mounted in-line down the length of the step feeder. With the mounting configuration at Collum’s Lumber, each sensor gathers data from approximately 8’ down the length of the log.

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MillTrak’s sensors accurately detect the log’s diameter and length and as well as its position. Two sensors are mounted in-line down the length of the step feeder. With the mounting configuration at Collum’s Lumber, each sensor gathers data from approximately 8’ down the length of the log. The MillTrak 3D system operates by measuring the distance from the surface of the sensor to all of the points in the sensor image. The accuracy of the system is dependent on the sensor’s position and distance from the log deck being monitored. The system allows the PLC to recognize the size and position of logs on the step feeder the same as a conventional proximity/range type detector. MillTrak 3D could also be used in an advanced log sorting application.

I chose MillTrak because of the support we get from USNR, and the simplicity of the MillTrak system.

Features and benefits of MillTrak 3D for log gap control include the following.

The MillTrak 3D system operates by measuring the distance from the surface of the sensor to all of the points in the sensor image. The accuracy of the system is dependent on the sensor’s position and distance from the log deck being monitored.

Closing the gap I nstallation requirements are reduced

to as little as mounting a few sensors and running one set of cables from each sensor to the MillTrak 3D computer system. Timing for logs being fed into the

conveyor can be adjusted based on the position of the log on the step feeder and the diameter of the log. The system simplifies PLC gap control

logic because logs are initially fed into the conveyor at the appropriate gap requiring less adjustment downstream by the PLC. The time required for cleaning of photo

sensors or proximity detectors is practically eliminated.

Gregg’s target for results was to increase the speed of the primary line and the overall throughput of the sawmill. “We’ve gained at least a log a minute through the process. I haven’t increased the speed of the DLI yet, this increase is just through more consistent log feeding. Now we are able to run a consistent log gap, and on shorter lumber it runs just as fast as with longer lumber.” He went on to explain that even one log/minute increase over the course of the mill’s daily 11-1/2 hour shift adds up to a very large number when calculated over time. He said, “It really is a monumental change.” He also relayed that the mill is processing 10% more logs through the DLI with the MillTrak 3D system.

That is close to 3,000 boards more than what we were doing before MillTrak. It really is a monumental change.

Gregg went on to compare the line before and after installation of the MillTrak 3D

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COLLUM'S LUMBER – CLOSING THE GAP appreciation for the role technology plays in today’s marketplace. “With this market the technology is overwhelming. You are either going to stay ahead of the game or get left behind.” Gregg says that he takes a keen interest in new developments and was impressed with USNR’s display when he attended the recent SFPA Expo in Atlanta, GA last June. He said that he was particularly impressed with USNR’s new ElectraTong Lug Loader and will be watching to visit an early installation. For now Collum’s Lumber is reaping the benefits of improved log feeding and increased throughput.

Video of the log gapping operation utilizing the MillTrak 3D system: http://vimeo.com/ 72006244

Top:The MillTrak 3D system user interface allows the operator to position and calibrate the sensors without manual intervention. Above: MillTrak 3D accurately models the diameter and length of each log, as well as its location on the step feeder.

system. For the ‘before’ scenario he took a typical shift where the log run averaged a small end diameter of 9.96”. That day the mill processed 43,533 pieces through the trimmer. For the ‘after’ scenario he chose a day where the log run averaged 9.4” small end diameter, and the mill’s total output through the trimmer was 46,203 pieces. He remarked, “That is close to 3,000 boards more than what we were doing before MillTrak. I’m 100% satisfied.” In fact, Gregg says that MillTrak 3D has become a key component of the primary line production.

Besides Gregg, owner Micky Scott had input into the project. The mill’s controls team of Marion Weathersbee and Jon Pye were deeply involved and received in-depth training on the new system. USNR’s Brent Reynolds, project manager, performed the installation and start-up as well as training of mill personnel.

Seizing oppor tunity Collum’s Lumber looks to continue its progression with more new technology as opportunities arise. Gregg expressed his

Millwide Insider | ISSUE 4 - 2013 | www.usnr.com

SFPA Show Review

Technology on parade USNR brought an abundance of technology for exhibitors to the SFPA-hosted Forest Products Machinery & Equipment Expo held at Atlanta, Georgia June 5 - 7, 2013. Garnering the largest footprint in the show, our booth was a hot spot for visitors to gather to talk about the industryâ&#x20AC;&#x2122;s latest developments and how USNRâ&#x20AC;&#x2122;s technology can solve their processing challenges.

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SFPA SHOW REVIEW

Preceding page: Our Transverse High Grader (THG) was the center of much discussion with the recent announcement of the pending installation at Deltic Timber, Waldo, Arkansas, the heart of the southern US region. The display included USNR’s Grade Projector for projecting grades onto lumber as a component of the THG line. Top: The ElectraTong™ Lug Loader was introduced at the show as USNR’s newest lumber handling innovation. You can read more about this all-electric board feeding system on page 22.

Video of the TransLineator board feeding system: http://vimeo.com/ 60470926

Millwide Insider | ISSUE 4 - 2013 | www.usnr.com

Video of the Grade Projector system: http://vimeo.com/ 59952232

Left: The TransLineator™ board feeding system had its first showing in the southern US region by way of a model. This revolutionary consolidated board feeding concept was recently installed in a planer outfeed application at a mill in Oregon.

Top left and right: Every corner of the USNR booth was more often than not jam packed with interested and curious visitors. Right: USNR’s Counter-Flow Kiln model was displayed with MyMill™ mobile control. With 10 MyMill mobile sorter control systems sold, the technology has recently been transitioned for lumber dry kiln applications and was also used at the show to demonstrate control of the Multi-Track Fence, pictured at bottom right. Below left: Our MillTrak™ 3D model demonstrated the technology’s capabilities. Below right: The Multi-Track Fence operation was demonstrated and, as usual, played to a crowd.

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ElectraTong™ Lug Loader It does not require incoming backlog pressure to deal the board. Instead it has the ability to pick up a piece off the infeed belts with no backlog forces. Because no backlog pressure is required it handles feathered edge material well when coupled with a MillTrak backlog camera. The infeed belts index on a board-width basis, allowing it to provide optimum board control at high speeds. ElectraTong is also tolerant of variable thicknesses down the length of a piece, and easily handles feathered boards and waned-out pieces. It will tolerate a wide range of thicknesses between boards (eg. 1” to 4”) allowing it to excel in random thickness green mill applications. It is reliable at high speeds (250+ LPM can be achieved).

Superior design

The industry’s first all-electric lug loader is here! USNR’s ElectraTong Lug Loader is a truly unique solution. During operation and even at high speeds it provides excellent board control. It excels in random thickness applications and handles feather edge material well. ElectraTong can be coupled with the MillTrak™ backlog sensor for the ultimate in board feeding control. There was an awful lot of buzz at the recent SFPA Expo show in Atlanta, Georgia about USNR’s latest lumber handling achievement – our all-electric board feeder, dubbed ElectraTong. Following are some of this new product’s unique features.

Configurable clamping force

accommodates handling of appearance grades or timbers Infeed belts index on a board-width

basis for excellent board control at very high speeds

All electric actuation – no hydraulics,

Easily handles feather edge material

no air, and no rubber bands

Excels in random thickness applications

(1”-4”)

Electric drives rotate shafts to actuate

the claws

Designed for easy access, maintenance

Independently configurable

clamp/ unclamp Planer mill clamp/unclamp positions

can be configured by product

Superior capabilities The ElectraTong Lug Loader truly shines in high speed, random thickness applications.

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Unlike other claw style machines on the market it features all electric actuation, with no hydraulics, no air, and no rubber bands. The ElectraTong utilizes five electric drives to rotate through-shafts that actuate the claws. Electric drives are controlled through modern slip ring communication. Programmable clamp and unclamp positions are easily adjusted through USNR’s WinTally™ or a stand-alone controller. For planer mill applications clamp and unclamp positions can be configured by product. Clamping of variable thickness pieces is achieved through Rosta tensioners mounted on each claw. The tensioners allow more force to be applied to thick products, and more travel for thin products. A separate Rosta tensioner is built into the throughshaft assembly to isolate the electric drives from impact, and to allow further thickness range adjustment. Belts are used on the infeed and outfeed to better control the dealing process. For information about this unique new product please contact us at 800.BUY.USNR, +360.225.8267 or info@usnr.com.

New Projects AKD Softwoods – BioLuma Edger, Trimmer Opt. upgrades AKD Softwoods at Colac, Australia is investing to update its Edger and Trimmer optimization lines with advanced scanning technology from USNR.

BioVision Edger The Edger optimization system will implement USNR’s BioVision technology. The BioVision system will employ the latest MillExpert™ software platform release and a new scan frame outfitted with BioLuma 2900LV sensors. The HD laser profiling and HD visual data will be collected and fed to the system’s MillExpert software to maximize both total recovery and value recovery of structural and appearance grade products, by positioning the saws based on knot sizing permitted for structural lumber.

Option for BioVision Trimmer The Trimmer optimization system will also take advantage of the latest MillExpert platform, and will be paired with BioLuma 2900L HD laser profiling sensors. Once the systems are running the mill plans to conduct testing to evaluate the payback to add BioVision capability to the Trimmer line.

Deltic Timber – Batch Kiln, Green Burner, Kiln Boss PLC USNR’s double-track batch Dry Kiln, Kiln Boss controls and Green Burner technology is being implemented at the Deltic Timber operation at Ola, Arkansas. The hightemperature kiln will be fueled by USNR’s Sloped Grate Green Burner.

insulated blend box, and put back into the kiln at 500° F. This afterburner provides complete combustion, keeping lumber in the kiln remarkably clean and free from ash.

Lakeland Mills – MyMill mobile sor ter control USNR’s MyMill™ mobile sorter control and WinTally™ sorter management technologies will be implemented at the Lakeland Mills operation at Prince George, BC. These advanced systems will improve the flow and management of dimensional lumber products at the mill’s sawmill sorter line.

MyMill Mobile Machine Control MyMill is a software suite developed by USNR that enables mill personnel to interact with mill processing equipment using mobile devices such as iPads and iPods. MyMill replicates, in a mobile device, all of the functionality that is typically available through a stationary HMI touchscreen. MyMill can be configured for any wood processing system where a stationary HMI would typically be desired.

Lecours Lumber – V7.2 Trimmer upgrade The mill, located at Calstock, Ontario, is upgrading its 20-year-old trimmer optimization system to the latest Newnes Sawmill Suite (NSS) version release. The NSS V7.2 upgrade will allow Lecours Lumber to improve recovery and

throughput for its operation, and bring the trimmer optimization system to today’s processing standards.

Pukepine Sawmills – Grade Scanning Trimmer Optimization System USNR’s BioVision technology is advancing on the land down under with an order for a new grade scanning system to be installed at Pukepine Sawmills, Te Puke, New Zealand. The order includes a MultiTrack Positioning Fence, 6M (20’) USNR Grade Scanning Trimmer Optimizer system featuring BioLuma 2900LVG+ scanning, and V7.2 Transverse Cant Optimizer software / hardware upgrade. The BioLuma™ 2900LVG+ sensors together with proven optimization, defect recognition and classification, provide the basis for this world-class sawmill automated grading system. These BioLuma sensors are unique in the marketplace, offering fully integrated GrainMap™, HD color vision and HD laser profiling. Grain Map grain angle measurement affords more comprehensive defect analysis, allowing the optimizer to detect and classify more defects. Proven algorithms provide the most valuable cut solution utilizing, product setup information as input by the mill user, board measurements from the sensors and available operator inputs.

Cleanest, high value lumber The Green Burner’s unique Turbo Technology™ produces the cleanest, high value lumber. The cyclonic afterburner located just after the main burner chamber, sets the Green Burner apart from ordinary sawdust burner systems. This proprietary system enables temperatures in the afterburner to get much higher than temperatures in the main burner, where sawdust is initially fed. Heated air from the burner at 2000° F is blended with 200° F return air from the kiln in the USNR

COMPLIMENTARY SUBSCRIPTION For your complimentary subscription to USNR’s Millwide Insider magazine e-mail subscriptions@usnr.com or go to www.usnr.com/about/news

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PO Box 310 Woodland, WA 98674

Millwide Insider is printed on recycled paper.

Profile Randy Layton is an Account Manager for USNR. He is based at Woodland, Washington. Randy brings nearly 35 years of experience in the sawmill industry to assist USNR’s customers in the Pacific Northwest US region. His career started with USNR in 1989, but prior to that he honed his electrical engineering skills while serving in the US Air Force and while attending Portland State University.

planning capital investments for their operations. Randy comments, “I’ve seen the technology and the industry grow through the years, and I’m glad to be able to grow with it.” Randy enjoys fishing and spending time with his grandchildren during his off hours.

Randy’s knowledge offers customers a wealth of experience to draw on when

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