Sawmill

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Introduction

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.

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.

Update Dec. 2, 2008: Based on a comment from our blog, we decided to pursue a circular blade mill, one like the Mobile Dimensions Saw.

Collaboration

Review of Project Status

Nov. 2008: Robert Todd is entering as project manager. 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.

Local Sawmills

  1. http://simpsons-nativehardwoods.com/page7.html - St. Joseph, MO
  2. Watkins Sawmill - Stewartsville, MO - (816) 669-3218

Sawmill - Current Work

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:

Pto motor.jpg

Here is the hookup diagram:

Pto motor hookup.jpg

Note: Since we have 3600 PSI available, we can run 2 of these motors in series to match available power more closely.

A very preliminary prototype drawing, top view: Sawmill picture 2D top.jpg

Sawmill - Developments Needed

Sawmill - General

Design developments

Oct 2008: We are still narrowing down an option for the sawmill. We are considering a chainsaw mill, and here are some comments on multipurpose sawmills

Jan 2009 developments:

Jan. 2, 09: 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/ Looked into space frames like the MDS frame. http://en.wikipedia.org/wiki/Space_frame Read about trusses. http://en.wikipedia.org/wiki/Truss

Need to learn the calculations for materials.

Need to contact Ben and ask questions about the MDS and sawmill.

Where can blades be bought from?

Jan. 4, 09: 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.

Could the saw assembly use a swing blade system for reduced cost? It would have to be stable though. http://www.skillmill.com/index.htm http://www.petersonsawmills.com/products_asm.htm http://www.truthaboutax.com/site/1515517/page/875294

Dimension sawmills appear to have the highest output: http://forestry.about.com/cs/portamills/a/portamill_inter_3.htm

Circular saw blades appear to be easy to manufacture, repair, and have a good lifetime. http://www.woodweb.com/knowledge_base/Sawmill_recovery_rate.html

Price comparison of sawmills http://www.woodsmansawmillcompany.com/

30" blades seem too expensive for most opearations, a 20" blade might work and be much more affordable currently. Cheapest 30" $1200: 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

Cheapest 20" $150: 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

Jan 13: Made 2d design and worked on bill of materials.

Sawmill Design Rationale

1. 3 blade System, circular 2. Main blade, 30" 3. Main blade RPM - 2000 RPM 4. Edger blades - 5000 RPM 5. 2 edger blades are adjustable - pins? 6. 2 edger blades on same axle 7. Flat mounting of sawblades via recessed screwholes to spindle - not necessary 8. Simple pulley system, with single pulley of 3x for main blade 9. Hydraulic motor around 700 RPM 10. Double pulley for edger blades, about 2.5 ratio for each 11. 2 hydraulic motors are utilized 12. 2 Cushion valves are used for stopping in bidirectional configuration 13. Tractor log loading onto platform 14. Move onto hydraulic log handling later 15. Move on to automatic sawmill operation with remote control, for ease of cutting. 16. Hydraulic motors utilize 24 gpm at up to 3600 PSI 17. Power is about 40 hp - available from 55 hp Deutz, at .72 system efficiency 18. 4x4s and flat 2x of large width - width is half of main blade size 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 20. Allow for log turning in addition to taking slices out of the wood 21. Each motor is 40 hp 22. 2 spool control valve needs to handle the full fluid flow (24 gpm) to each motor 23. Safety cage around blades 24. Blade cooling soapy water 25. Track will be 12 feet for now 26. Track handles 3000 lb logs 27. Logs loaded with tractor loader 28. Mechanism to secure log to track 29. use bearings to ride on a flat track


Bill of Materials

system at 3600 psi, 24 gpm


Base frame

Approx. 3.5-4in wide/high x 19ft long "I" beams x2


Track frame

Approx. 3.5-4in wide/high x 8ft long "I" beams x5

Gear rack, about 6ft long x 1-2in wide


Log clamps

threaded shaft

handle

metal pieces ("L" shape?)

shaft bearing?


Jacks

threaded shaft

handle

shaft bearing?

base pad


Space frame

2in "L" angle approx. 17-18ft x4

2in x 18in steel x? 2in x ? steel braces x?

Large Gears x2

Small Gears x2

Gear Pipe

Gear pipe bearings x3

Gear pipe handle

metal for holding small gears

metal for holding bearings


Saw Platform


Frame

2in x 1/8in x 20in steel x12

metal to hold bearings


Vertical asssembly

6ft? "I" beams x2

2 stopper L pieces for top and bottom about 2ft wide

pulley cable

pulley mount and wheel on top

pulley handle with locking teeth (spring tensioned?)


Saw Motor Frame

2 hydraulic motors - 40 hp each, 3600 psi

2 cushion valves, 24 gpm, 3600 psi

2 spool, 25 gpm valve

Hydraulic Hoses

Motor couplers

Motor coupler, main

Motor coupler, secondary

1 pulley,2.5x

2 pulley system, 2.5x each

1 main belt

2 secondary pulley belts

Main saw blade - 20"

2 edger blades - 9"

2 shafts for blades

3 attachments systems for blade - Multimachine style

2 sets of 2 pillow blocks to hold blade shafts


Ball bearings and bearing shafts x48

16 for space frame track

16 for saw assembly frame

16 for vertical saw assembly


Bolts and nuts


Need cost sourcing for all pieces.

Implementation

0. With design rationale, put it up for review on Red Pages 1. Start with purchasing one blade, 30", 2 blades, 12" 2. Build track for log handling 3. Build cutting head - gear up the blade 4. Install all safety devices before operating 5. Test sawmill operation without blades attached 6. Start with unidirectional cutting head, move on to bidirectional by upgrade

Platform Function Rationale

Needs a platform that will be able to hold the weight of the motors, pulley system, blades, and frame. The weight of the platform will be about 25 lb. per motor, etc for a total of about 200 lbs. The platform must be stable enough to make straight cuts. The platform should be able to roll in the x axis. The platform must move precisely and hold securely in the y and z axes. The y and z axis movements must be about 3-4 feet for large logs.

Sawmill - Specific

Sawmill - Background Debriefing

Sawmill - Information Work

Sawmill - Hardware Work

Sawmill - Sign-in

Development Work Template

  1. Sawmill - Product Definition
    1. Sawmill - General
    2. Sawmill - General Scope
    3. Sawmill - Product Ecology
      1. Sawmill - Localization
      2. Sawmill - Scaleability
      3. Sawmill - Analysis of Scale
      4. Sawmill - Lifecycle Analysis
    4. Sawmill - Enterprise Options
    5. Sawmill - Development Approach
      1. Sawmill - Timeline
      2. Sawmill - Development Budget
        1. Sawmill - Value Spent
        2. Sawmill - Value available
        3. Sawmill - Value needed
    6. Sawmill - Deliverables and Product Specifications
    7. Sawmill - Industry Standards
    8. Sawmill - Market and Market Segmentation
    9. Sawmill - Salient Features and Keys to Success
  2. Sawmill - Design Evolution
  3. Sawmill - Technical Design
    1. Sawmill - Product System Design
      1. Sawmill - Diagrams and Conceptual Drawings
        1. Sawmill - Pattern Language Icons
        2. Sawmill - Structural Diagram
        3. Sawmill - Funcional or Process Diagram
        4. Sawmill - Workflow
      2. Sawmill - Technical Issues
      3. Sawmill - Deployment Strategy
      4. Sawmill - Performance specifications
      5. Sawmill - Calculations
        1. Sawmill - Design Calculations
        2. Sawmill - Yields
        3. Sawmill - Rates
        4. Sawmill - Structural Calculations
        5. Sawmill - Power Requirements
        6. Sawmill - Ergonomics of Production
        7. Sawmill -Time Requirements
        8. Sawmill - Economic Breakeven Analysis
        9. Sawmill - Scaleability Calculations
        10. Sawmill - Growth Calculations
      6. Sawmill - Technical Drawings and CAD
      7. Sawmill - CAM Files
    2. Sawmill - Component Design
      1. Sawmill - Diagrams
      2. Sawmill - Conceptual drawings
      3. Sawmill - Performance specifications
      4. Sawmill - Performance calculations
      5. Sawmill - Technical drawings and CAD
      6. Sawmill - CAM files whenever available
    3. Sawmill - Subcomponents
  4. Sawmill - Deployment and Results
    1. Sawmill - Production steps
    2. Sawmill - Flexible Fabrication or Production
    3. Sawmill - Bill of materials
    4. Sawmill - Pictures and Video
    5. Sawmill - Data
  5. Sawmill - Documentation and Education
    1. Sawmill - Documentation
    2. Sawmill - Enterprise Plans
  6. Sawmill - Resource Development
    1. Sawmill - Identifying Stakeholders
      1. Sawmill - Information Collaboration
        1. Sawmill - Wiki Markup
        2. Sawmill - Addition of Supporting References
        3. Sawmill - Production of diagrams, flowcharts, 3D computer models, and other qualitative information architecture
        4. Sawmill - Technical Calculations, Drawings, CAD, CAM, other
      2. Sawmill - Prototyping
      3. Sawmill - Funding
      4. Sawmill - Preordering working products
      5. Sawmill - Grantwriting
      6. Sawmill - Publicity
      7. Sawmill - User/Fabricator Training and Accreditation
      8. Sawmill - Standards and Certification Developmen
      9. CEB - Other
    2. Sawmill - Grantwriting
      1. Sawmill - Volunteer grantwriters
      2. Sawmill - Professional, Outcome-Based Grantwriters
    3. Sawmill - Collaborative Stakeholder Funding
    4. Sawmill - Tool and Material Donations
    5. Sawmill - Charitable Contributions
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