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| {{Site header}} | | {{OrigLang}} |
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| | {{GVCS Header}} |
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| =Introduction= | | ==Overview== |
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| Sawmill - highly versatile and valuable lumber if woodlot is available - or lumber may be bought from neighbors. Decentralized sawmilling may obviate clear-cut lumber companies in a new economy. Many uses. Flex fab opportunity. Lends itself highly to the type of modular structures proposed by the Center for Maximum Potential Building Systems - look for GreenForms at http://cmpbs.org/flash/download.htm . Lends itself highly for flex fab production, especially kits. Fabrication is absolutely simple - after metal is cut - only a drill press is required. Zero welds in structure, with minor welding for motor attachments. DfD, lifetime design. Driven by a hydraulic motor powered from tractor hydraulics.
| | A sawmill converts felled logs from trees into green wood lumbar. As a piece of the [[GVCS]], it unlocks a range of well-established wood construction techniques. |
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| As a first attempt at a robust and replicable sawmill, we are proposing a chainsaw mill, like a Logosol, with a 25 hp hydraulic motor.
| | To convert the green wood into finished dried lumber the cut boards are either [[kiln| air-dried]] or fired in a [[kiln]]. |
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| '''Update Dec. 2, 2008:''' Based on a [http://openfarmtech.org/weblog/?p=407#comments comment from our blog], we decided to pursue a circular blade mill, one like the [http://www.mobilemfg.com Mobile Dimensions Saw].
| | ==Detailed Description== |
| | <html> |
| | <iframe src="https://player.vimeo.com/video/28369397?title=0&byline=0&portrait=0" width="400" height="233" frameborder="0"></iframe> |
| | </html> |
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| The current prototype is a dimensional sawmill. In a dimensional sawmill the log is stationary while the blades and motors move. They have 3 circular saw blades: one main vertical blade, and 2 smaller horizontal blades. They cut a whole piece of lumber, like a 2 inch by 4 inch board, in each pass.
| | ==Product Ecology== |
| | [[Image:4b-Constructioneco.png|600px|right]] |
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| =Collaboration=
| | {{Product Ecology |
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| ==Review of Project Status== | | |Product={{Sawmill}} |
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| Nov. 2008: Robert Todd is entering as project manager.
| | |From= |
| Dec. 2008: Jeremy Mason is entering the project onsite, until Robert returns to Factor e Farm. At that point, Jeremy and Robert will work together.
| | * {{Furnace}} |
| | * {{Welder}} |
| | * {{Multimachine}} |
| | * {{Hydraulic Motor}} |
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| ==Local Sawmills== | | |Uses= |
| | * [[Wood]] |
| | * {{PowerCube}} |
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| #http://simpsons-nativehardwoods.com/page7.html - St. Joseph, MO
| | |Creates= |
| #Watkins Sawmill - Stewartsville, MO - (816) 669-3218
| | * [[Sawdust]] |
| | * [[Lumber]] |
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| ==Sawmill - Current Work== | | |Enables= |
| | * {{Pelletizer}} |
| | * {{Hammermill}} |
| | * [[Kiln]] |
| | * [[Workshop]] |
| | * [[Greenhouse]] |
| | * [[Hab Lab]] |
| | * [[RepLab]] |
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| We have a hydraulically-driven PTO motor as a start. It will be powered by [[LifeTrac]]. All hoses are already available - it is part of our flexible open source tractor infrastructure. Here are the motor specifications, from Surpluscenter.com:
| | |Components= |
| | *Blade |
| | *Structure |
| | *Bed |
| | *Gantry |
| | *Bearings |
| | *[[Hydraulic Hoses]] |
| | *[[Control Box]] |
| | }} |
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| [[Image:pto_motor.jpg]] | | ==Status== |
| | [[Image:Sawmill2.jpg|right]] |
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| Here is the hookup diagram:
| | The first Sawmill prototype is currently under construction as a part of the [[GVCS Rollout Plan]]. |
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| [[Image:pto_motor_hookup.jpg]] | | See [[Dimensional_Sawmill_Prototype_I]] for in-progress videos. |
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| '''Note''': Since we have 3600 PSI available, we can run 2 of these motors in series to match available power more closely.
| | ==Videos== |
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| A very preliminary prototype drawing, top view:
| | {{video}} |
| [[Image:Sawmill_picture_2D_top.jpg]]
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| == Sawmill - Developments Needed== | | ==See Also== |
| === Sawmill - General===
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| ====Design developments====
| | *[[Sawmill - Design Rationale]] |
| '''Oct 2008:'''
| | *[[Sawmill Design]] |
| We are still narrowing down an option for the sawmill. We are considering a chainsaw mill, and here are some [[comments on multipurpose sawmills]]
| | *[[Sawmill Analysis]] |
| | *[[Sawmill/Research_Development|Research]] |
| | *[[Sawmill Archive]] |
| | *[[Cut-to-Length Logging]] |
| | *[[Wood]] |
| | *[[Forest]] |
| | *[[Kiln]] |
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| '''Jan 2009 developments:'''
| | ==Links== |
| | * [http://en.wikipedia.org/wiki/Sawmill Wikipedia: Sawmill] |
| | * [http://en.wikipedia.org/wiki/Portable_sawmill Wikipedia: Portable Sawmill] |
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| '''Jan. 2, 09:''' | | ===Theo's Github Repository=== |
| We decided that the MDS design looks pretty straightforward and that it should be used as the base for the OS sawmill. http://www.mobilemfg.com/
| | https://github.com/Veradrix90/Dimensional-Sawmill |
| Looked into space frames like the MDS frame. http://en.wikipedia.org/wiki/Space_frame
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| Read about trusses. http://en.wikipedia.org/wiki/Truss
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| Need to learn the calculations for materials.
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| Need to contact Ben and ask questions about the MDS and sawmill.
| | {{GVCS Footer}} |
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| Where can blades be bought from?
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| '''Jan. 4, 09:'''
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| We have narrowed down the design to something similar to the MDS space frame (for stability) on two 'I' beams for x and y axis movements, a chassis surrounding the space frame with bearings to grip it on all sides, a vertical plate or beams on the chassis with another plate attached with bearings and adjusted vertically with a pulley for the z axis, the MDS like saws are mounted on the vertically moving plate and powered with hydraulic motors and pulleys to get the correct RPMs.
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| Could the saw assembly use a swing blade system for reduced cost? It would have to be stable though.
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| http://www.skillmill.com/index.htm
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| http://www.petersonsawmills.com/products_asm.htm
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| http://www.truthaboutax.com/site/1515517/page/875294
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| '''Jan 13:'''
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| Made 2d design and worked on bill of materials.
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| ====Sawmill Research====
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| Dimension sawmills appear to have the highest output:
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| http://forestry.about.com/cs/portamills/a/portamill_inter_3.htm
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| <blockquote>
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| For production, a chainsaw mill can mill 200 to 400 board feet per day, a band mill can mill 800 to 2,000 board feet per day, swing mills can produce 1,500 to 3,000 board feet per day and dimension mills 2,000 to 4,000 board feet per day. A lot depends on log size, species and products being cut.
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| </blockquote>
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| Circular saw blades appear to be easy to manufacture, repair, and have a good lifetime.
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| http://www.woodweb.com/knowledge_base/Sawmill_recovery_rate.html
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| Price comparison of sawmills
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| http://www.woodsmansawmillcompany.com/
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| {| cellpadding="1" cellspacing="1" style="margin:3px; border:3px solid #000000;" | |
| |-
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| |align="left"| ||align="left"| ||
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| |Woodsman||$12,000
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| |Lucas||$13,000
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| |Peterson||$20,000
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| |Mobile Dimension||$25,000
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| |Mighty Mite||$30,000
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| |}
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| 30" blades seem too expensive for most operations, a 20" blade might work and be much more affordable currently.
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| Cheapest 30" $1200:
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| http://www.amazon.com/Lackmond-CW1301751-Walk-Behind-Concrete-Blades/dp/B00112W9L4/ref=sr_1_10?ie=UTF8&s=hi&qid=1231132591&sr=1-10
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| Cheapest 20" $150:
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| http://www.amazon.com/Amana-720360-Heavy-Duty-Ripping-Blades/dp/B000P4HN2Y/ref=sr_1_29?ie=UTF8&s=hi&qid=1231132318&sr=1-29
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| ====Sawmill Design Rationale====
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| 1. 3 blade System, circular
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| 2. Main blade, 30"
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| 3. Main blade RPM - 2000 RPM
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| 4. Edger blades - 5000 RPM
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| 5. 2 edger blades are adjustable - pins?
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| 6. 2 edger blades on same axle
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| 7. Flat mounting of sawblades via recessed screwholes to spindle - not necessary
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| 8. Simple pulley system, with single pulley of 3x for main blade
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| 9. Hydraulic motor around 700 RPM
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| 10. Double pulley for edger blades, about 2.5 ratio for each
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| 11. 2 hydraulic motors are utilized
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| 12. 2 Cushion valves are used for stopping in bidirectional configuration
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| 13. Tractor log loading onto platform
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| 14. Move onto hydraulic log handling later
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| 15. Move on to automatic sawmill operation with remote control, for ease of cutting.
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| 16. Hydraulic motors utilize 24 gpm at up to 3600 PSI
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| 17. Power is about 40 hp - available from 55 hp Deutz, at .72 system efficiency
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| 18. 4x4s and flat 2x of large width - width is half of main blade size
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| 19. To use power effectively, one should be able to control the amount of flow to each of the two motors, from full power in one to full power in the other
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| 20. Allow for log turning in addition to taking slices out of the wood
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| 21. Each motor is 40 hp
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| 22. 2 spool control valve needs to handle the full fluid flow (24 gpm) to each motor
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| 23. Safety cage around blades
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| 24. Blade cooling soapy water
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| 25. Track will be 12 feet for now
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| 26. Track handles 3000 lb logs
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| 27. Logs loaded with tractor loader
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| 28. Mechanism to secure log to track
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| 29. use bearings to ride on a flat track
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| ====Bill of Materials====
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| system at 3600 psi, 24 gpm
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| '''Base frame'''
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| Approx. 3.5-4in wide/high x 19ft long "I" beams x2
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| '''Track frame'''
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| Approx. 3.5-4in wide/high x 8ft long "I" beams x5
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| Gear rack, about 6ft long x 1-2in wide
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| '''Log clamps'''
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| threaded shaft
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| handle
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| metal pieces ("L" shape?)
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| shaft bearing?
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| '''Jacks'''
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| threaded shaft
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| handle
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| shaft bearing?
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| base pad
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| '''Space frame'''
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| 2in "L" angle approx. 17-18ft x4
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| 2in x 18in steel x?
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| 2in x ? steel braces x?
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| Large Gears x2
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| Small Gears x2
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| Gear Pipe
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| Gear pipe bearings x3
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| Gear pipe handle
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| metal for holding small gears
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| metal for holding bearings
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| '''Saw Platform'''
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| '''Frame'''
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| 2in x 1/8in x 20in steel x12
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| metal to hold bearings
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| '''Vertical asssembly'''
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| 6ft? "I" beams x2
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| 2 stopper L pieces for top and bottom about 2ft wide
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| pulley cable
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| pulley mount and wheel on top
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| pulley handle with locking teeth (spring tensioned?)
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| '''Saw Motor Frame'''
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| 2 hydraulic motors - 40 hp each, 3600 psi
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| 2 cushion valves, 24 gpm, 3600 psi
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| 2 spool, 25 gpm valve
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| Hydraulic Hoses
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| Motor couplers
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| Motor coupler, main
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| Motor coupler, secondary
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| 1 pulley,2.5x
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| 2 pulley system, 2.5x each
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| 1 main belt
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| 2 secondary pulley belts
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| Main saw blade - 20"
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| 2 edger blades - 9"
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| 2 shafts for blades
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| 3 attachments systems for blade - Multimachine style
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| 2 sets of 2 pillow blocks to hold blade shafts
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| '''Ball bearings and bearing shafts''' x48
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| 16 for space frame track
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| 16 for saw assembly frame
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| 16 for vertical saw assembly
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| '''Bolts and nuts'''
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| Need cost sourcing for all pieces.
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| ====Implementation====
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| 0. With design rationale, put it up for review on Red Pages
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| 1. Start with purchasing one blade, 30", 2 blades, 12"
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| 2. Build track for log handling
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| 3. Build cutting head - gear up the blade
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| 4. Install all safety devices before operating
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| 5. Test sawmill operation without blades attached
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| 6. Start with unidirectional cutting head, move on to bidirectional by upgrade
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| ====Platform Function Rationale====
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| Needs a platform that will be able to hold the weight of the motors, pulley system, blades, and frame.
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| The weight of the platform will be about 25 lb. per motor, etc for a total of about 200 lbs.
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| The platform must be stable enough to make straight cuts.
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| The platform should be able to roll in the x axis.
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| The platform must move precisely and hold securely in the y and z axes.
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| The y and z axis movements must be about 3-4 feet for large logs.
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| === Sawmill - Specific===
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| ==== Sawmill - Background Debriefing====
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| ==== Sawmill - Information Work====
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| ==== Sawmill - Hardware Work====
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| == Sawmill - Sign-in==
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| =Development Work Template=
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| #[[Sawmill - Product Definition]]
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| ##[[Sawmill - General]]
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| ##[[Sawmill - General Scope]]
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| ##[[Sawmill - Product Ecology]]
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| ###[[Sawmill - Localization]]
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| ###[[Sawmill - Scaleability]]
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| ###[[Sawmill - Analysis of Scale]]
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| ###[[Sawmill - Lifecycle Analysis]]
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| ##[[Sawmill - Enterprise Options]]
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| ##[[Sawmill - Development Approach]]
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| ###[[Sawmill - Timeline]]
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| ###[[Sawmill - Development Budget]]
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| ####[[Sawmill - Value Spent]]
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| ####[[Sawmill - Value available]]
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| ####[[Sawmill - Value needed]]
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| ##[[Sawmill - Deliverables and Product Specifications]]
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| ##[[Sawmill - Industry Standards]]
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| ##[[Sawmill - Market and Market Segmentation]]
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| ##[[Sawmill - Salient Features and Keys to Success]]
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| #[[Sawmill - Design Evolution]]
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| #[[Sawmill - Technical Design]]
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| ##[[Sawmill - Product System Design]]
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| ###[[Sawmill - Diagrams and Conceptual Drawings]]
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| ####[[Sawmill - Pattern Language Icons]]
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| ####[[Sawmill - Structural Diagram]]
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| ####[[Sawmill - Funcional or Process Diagram]]
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| ####[[Sawmill - Workflow]]
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| ###[[Sawmill - Technical Issues]]
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| ###[[Sawmill - Deployment Strategy]]
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| ###[[Sawmill - Performance specifications]]
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| ###[[Sawmill - Calculations]]
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| ####[[Sawmill - Design Calculations]]
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| ####[[Sawmill - Yields]]
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| ####[[Sawmill - Rates]]
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| ####[[Sawmill - Structural Calculations]]
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| ####[[Sawmill - Power Requirements]]
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| ####[[Sawmill - Ergonomics of Production]]
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| ####[[Sawmill -Time Requirements]]
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| ####[[Sawmill - Economic Breakeven Analysis]]
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| ####[[Sawmill - Scaleability Calculations]]
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| ####[[Sawmill - Growth Calculations]]
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| ###[[Sawmill - Technical Drawings and CAD]]
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| ###[[Sawmill - CAM Files]]
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| ##[[Sawmill - Component Design]]
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| ###[[Sawmill - Diagrams]]
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| ###[[Sawmill - Conceptual drawings]]
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| ###[[Sawmill - Performance specifications]]
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| ###[[Sawmill - Performance calculations]]
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| ###[[Sawmill - Technical drawings and CAD]]
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| ###[[Sawmill - CAM files whenever available]]
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| ##[[Sawmill - Subcomponents]]
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| #[[Sawmill - Deployment and Results]]
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| ##[[Sawmill - Production steps]]
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| ##[[Sawmill - Flexible Fabrication or Production]]
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| ##[[Sawmill - Bill of materials]]
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| ##[[Sawmill - Pictures and Video]]
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| ##[[Sawmill - Data]]
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| #[[Sawmill - Documentation and Education]]
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| ##[[Sawmill - Documentation]]
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| ##[[Sawmill - Enterprise Plans]]
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| #[[Sawmill - Resource Development]]
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| ##[[Sawmill - Identifying Stakeholders]]
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| ###[[Sawmill - Information Collaboration]]
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| ####[[Sawmill - Wiki Markup]]
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| ####[[Sawmill - Addition of Supporting References]]
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| ####[[Sawmill - Production of diagrams, flowcharts, 3D computer models, and other qualitative information architecture]]
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| ####[[Sawmill - Technical Calculations, Drawings, CAD, CAM, other]]
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| ###[[Sawmill - Prototyping]]
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| ###[[Sawmill - Funding]]
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| ###[[Sawmill - Preordering working products]]
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| ###[[Sawmill - Grantwriting]]
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| ###[[Sawmill - Publicity]]
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| ###[[Sawmill - User/Fabricator Training and Accreditation]]
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| ###[[Sawmill - Standards and Certification Developmen]]
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| ###[[CEB - Other]]
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| ##[[Sawmill - Grantwriting]]
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| ###[[Sawmill - Volunteer grantwriters]]
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| ###[[Sawmill - Professional, Outcome-Based Grantwriters]]
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| ##[[Sawmill - Collaborative Stakeholder Funding]]
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| ##[[Sawmill - Tool and Material Donations]]
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| ##[[Sawmill - Charitable Contributions]]
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