Self-Adjusting Machine Technology Leverages Scan Data to Improve Mill Processes

USNR’s Self-Adjusting Machine (SAM) technology automates the size control process. SAM effectively replaces many quality control functions typically performed manually. This new technology has been running in production since 2017.

Imagine a mill where products are quality controlled through technology, where mill QC staff are deployed for higher level analytical work. Manual quality control measurement for PLC correction is seldom required. Only then is it possible to operate the mill at its peak efficiency, value recovery, throughput performance, and safety.

SAM Technology brings you the future. • Automatic sawing variance control • Self-monitoring, self-adjusting machines • All pieces input/output scanned

Automated quality control systems have been available for years from third parties, but to fully close the loop the original optimization data is also required. For example, to automatically adjust the edger system it is necessary to know how the piece was positioned before the saws, as well as the measurements of the resulting piece. If the piece is not on size or not cut at the target location, it is important to know which saw is out of position, and the amount and direction that it needs to be adjusted. This is where USNR’s SAM technology closes the loop, providing complete data to automatically adjust the saws. USNR SAM technology has been operating in mills globally since 2017.

With USNR SAM technology, each piece is scanned before and after every cutting device. Scanning before the device is used by the optimizer to develop a breakdown solution, identify the current position of the piece, and set the machine’s cutting devices to optimally break down the piece. Scanning after the cutting device identifies how the piece was actually cut. Using the data trends from this second scan, SAM feeds corrections to the PLC.

Before each processing step, SAM measures the size, shape, and position of logs, cants, and flitches, and then measures them again after cutting using Flitch Matching™ technology.

USNR SAM technology combines the before-and-after measurements with the optimizer’s solution to:

• Determine the differences between what was intended to be cut, and what was actually cut. • Identify which saws, chippers, and positioners were used to process each piece.

After collecting a statistically significant set of samples, SAM calculates how to bias the PLC to minimize those errors, making recommendations for each saw, chipper, and positioner. The mill QC staff can choose to manually approve and implement the recommendations, or the USNR SAM technology can automatically implement them.

After being cut at the log line, flitches pile up in an unscrambler, and it’s not obvious to the human eye which log the flitch came from, or which saws and chippers produced it.

USNR’s patented Flitch Matching™ technology associates flitches with their parent log. The unique 3D shape characteristics of the flitch lets SAM identify each piece by comparing the flitch shape from the edger optimization scan to the original log line optimization scan. SAM can identify the parent of almost every piece, and also identify which cutting devices on the log line produced them. Feeding this data back to the log line lets SAM calculate PLC bias adjustments to help eliminate cutting errors.

SAM calculates and sends bias adjustments to the PLC to correct chipper and saw errors, and to correct machine positioning errors.

The same Flitch Matching technology is used to identify each cant, and the cutting devices upstream that produced the cant. At the gang, SAM calculates and sends bias adjustments to the PLC to correct chipper and saw errors.

SAM calculates and sends bias adjustments to the PLC to correct positioning pin errors and saw errors.

SAM calculates and sends bias adjustments to the PLC to correct fence positioning errors and saw errors. USNR is continually adding to this suite to provide the highest level of efficiency, value recovery, and safety.

UNSR SAM technology takes thousands of precise measurements on thousands of pieces each shift. It then calculates the off-size errors for pieces as they’re cut. The system evaluates the errors calculated for recent pieces, and at regular intervals, recommends PLC bias adjustments that will minimize the errors.

The bias recommendations are continuously updated as more pieces are measured, keeping the adjustments in sync with the current state of the machine.

• Improves uptime, efficiency, and throughput • More value, higher recovery; reduced off-size lumber • Target size reduction; smaller saw variation allowance • Immediate feedback; continuous monitoring and adjustment • Frees QC staff for higher-value analytical work using SAM’s trending data • Increases safety; reduces hands-on QC measurement • Available on systems with USNR optimization and PLC controls • Existing scanning systems are used whenever possible

USNR SAM Technology brings you the mill of the future.

Contact USNR for more information on this advanced technology at (800) 289-8767 or visit www.usnr.com.