SiCam SawTrack (Saw Monitoring)SiCam provides a variety of charts and histograms to show the trending behavior of saws. This information is broken down by saws for immediate probe

SiCam Systems Corporation

102 - 15910 Fraser Hwy. Suite 837 Surrey, BC V3S 2P3 Tel. 604.584.7151 Fax. 604.200.0132

www.sicamsystems.com

101-SiCamSP-RandomLengthGauge-v1.doc

SiCam SawTrack (Saw Monitoring)

Applications: Saw Deviation Monitor – Filer and Operator Feedback Bandsaw – Headrig, Twin, Quad, Resaw

Scanner Type: Inductive Probe – High Accuracy Inductive Probe

Enclosure: Steel case with UHMW Sleeve

The SiCam SawTrack system measures the deflection of the sawblade using a

inductive probe. Data is collected and used for immediate speed output opportunities and tracked for long term saw performance.

System Objective

Track the saw performance

Maximize the speed opportunities on the machine

Catch problem saws immediately and reduce saw wrecks

System Features

Monitor saw deflection performance

Track bandsaw guide wear

Optimize cutting tools change cycles

Predict repair & maintenance cycle trends

Tune optimization & controls

Minimize manufacturing variation

Reduce target sizes & increase throughput

http://www.sicamsystems.com/

SiCam Systems SawTrack V2

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SiCam SawTrack - Overview The SiCam SawTrack system fully integrates with all other SiCam products. The

system typically is paired with a cant and/or sideboard size control.

Probe mounts under saw guide

Probe stands off the saw blade

by ½”

Probes can read through oil, water, chip debris and are not affected by light reflections

Data is displayed for immediate results and trended for long term

performance


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SiCam SawTrack – Probe and Bracket

The inductive probes are designed and built for long term service in a harsh sawmill environment. Scanners are mounted to an adjustable bracket to provide adjustment and protection.

Solid machined steel enclosure

Adjustable mounting system for fine

tuning probe offset

Quick release probe with UHMW

sleeve

Probe mounts directly under the saw guide behind the gullet


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SiCam SawTrack – Interface SiCam SawTrack provides a variety of tools to display the current probe

information and trending performance. This section provides a high level view of a few of these interfaces

Custom HMI A high level interface that highlights all of the key indicators tracked related to size and saw monitoring. The following example monitors the performance of the

sawmill with a variety of size control and saw monitoring information. This high level view will provide supervisors and lead hands an indicator on equipment performance.

Key size control indicators

throughout the mill

High Level saw performance for a

Quad Bandmill machine

Quad indicators will go into warning

and alarm state to provide a warning to mill personal


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General Interface

SiCam provides a variety of charts and histograms to show the trending behavior of saws. This information is broken down by saws for immediate probe information and long term trending by piece over time.

Immediate Probe Data

The following screen is a realtime graph that flows from top to bottom with each bandmills performance

Average Piece Performance

The following example shows the average performance of a saw on each cut. This specific screen was captured with 25 teeth were knocked off the saw blade. The system can be configured to stop the line based on customer preferences.

Each bandmill is tracked in and out of the cut with a

realtime control chart

Speed Output information

is displayed as speed opportunities are sent to the PLC

Saw 3 average deflection

over the last few pieces

Actual sawblade that

caused this issue


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Saw Trending

SiCam brings long term trending to the saw deviation system and keeps long term performance information. The following graph shows the moving variation over an entire shift. Miss behaving saws are immediately identified.

Poorly behaving saws can

be removed from the mix if

required


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High Speed Outputs SiCam provides the option to provide OPTO22 outputs directly to the PLC for feedback. These outputs can enable the mill to speed up or slow down the line

based on immediate saw performance.

Light Box The lightbox/bar is available for customers that want to provide a simple light feedback to operators. This is particularly useful for single and double cut

headrigs.

OPTO22 configuration can setup any number of speed up or slow downs based on

customer requirements

Lights are configurable for any range based on saw

performance


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Speed Control Output Overview

The SiCam Saw Track System is designed to monitor the variation that occurs in one or more bandmills. This data is used for quality control, saw-filer feedback and speed control outputs.

The SiCam system uses highly accurate probes to monitor the deflection of the saw blade directly under the top guide. This deflection (saw deviation) is then used to determine saw performance and provide speed outputs.

Speed modifications are recommended by the SiCam system based on the

system configuration. Actual speed control and enhancement will occur in the PLC using the SiCam information. The PLC should be configured to monitor other possible variables such as motor draw, operator overrides, piece position

and other alarms. This document outlines the integration details required between the Saw Track

system and the existing control system. The system will monitor blocks of data or Digital I/O (Opto22) to provide the required feedback depending on system configuration.

Bandsaw Probes mounted on a twin

bandmill


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PLC Integration

SawTrack can integrate to the control system in a variety of methods. The most common integration uses Ethernet with a High Speed Opto22 Card. The Opto22 allows SiCam to send data very fast to the PLC and improve the reaction time.

The Saw Track system is flexible and will read/write any number of fields based on the system design. This section provides a guideline for typical twin and quad configurations. The system may be used as a stand-alone saw deflection

monitoring system of a fully integrated speed control enhancement.

PLC to SiCam Input Values

The following list contains a block of data typically read by SiCam during the saw

deflection monitoring process. Additional tracking information may also be available and can be added to the SiCam tracking. This block of data will be read once per piece passing through the machine.

Name Description Note

Log Number Optimizer Log ID

Cant Width Target Cant Width

Cant Thick Target Cant Thick/Height

Average Diameter Average Log Diameter

Min Diameter Min Log Diameter

Max Diameter Max Log Diameter

Log Length Log Length

Head 1 Position Chipping Head Position from Center

Head 2 Position Chipping Head Position from Center

Saw 1 Position Bandmill Position from Center

Saw 2 Position Bandmill Position from Center

Saw 3 Position Bandmill Position from Center Quad Only

Saw 4 Position Bandmill Position from Center Quad Only

Number of Left Sideboards Number of Left boards in solution

Number of Right Sideboards Number of Right boards in solution

Feed Speed Current Line Feed Speed

Bandmill Feed Speed Feed Speed at Bandmills

Side Head Feed Speed Feed Speed at Heads

Encoder Ticks Encoder Counter Value for Speed Feedback

Log Gap Gap setting between blocks

Bottom Head Feed Speed Top Profiling Head Feed Speed

Top Head Feed Speed Bottom Profiling Head Feed Speed

*All useful information should be written to this data block for improved reporting and tracking on the SiCam software side


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Communication Flow

The typical process of speed control/deflection monitoring will require input SiCam to read the appropriate signals and provide timely feedback for speed

changes. These steps outline a typical process of speed control for a single piece entering the machine.

The drawings show a Quad configuration with side chipping heads. The drawing shows 4 photoeyes between each machine on the Quad. The Saw Track system is only utilizing the last 3 photoeyes (B,C,D)

Note: Speed control zones will vary between machines so this section only outlines a simple integration.

Step 1 – Log Passes through Scanner

The log passes through the optimizer where a solution is made for this log. Since the B, C and D photoeyes are not blocked the SawTrack system is still checking for the “piece present” status.

Piece enters machine at optimizer commanded

speed


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Step 2 – Log Enters Chipping Heads The log enters the chipping heads but is still not in the Bandsaws. No speed enhancement or saw deviation monitor occurs until the second photoeye is

blocked (B).

Step 3 – Cant Hits First Set of Saws

Saw blocks the second photoeye and enters the cut. The SawTrack system begins monitoring the saw deflection. If the saw is performing well and the deviation remains low the system will put a speed increase in the PLC.

This variable should be applied to the current commanded speed to push the block through faster. If the saw continues to perform well the speed increases will continue every “n” scans.

As soon as the pre cut photoeye is blocked (B) the saw track system considers

the piece to be present and the saw deviation analysis begins.

Log proceeds into chipping heads at the commanded

speed

Saw hits the first set of saws and speeds can be modified

based on saws used and current deviation


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Step 4 – Cant Hits Second Set of Saws Saw the saw passes through the first set of saws and into the second the speed

control continues applying the speed up/down rules. If any saw begins to deviate beyond the tolerance the speed will no longer be increased and potentially decreased.

Step 5 – Cant Leaves the Saws and Sideboards Fall Finally as the piece leaves the saws and the last photoeye is cleared the piece is

recorded for tracking purposes and the next piece enters the machine.


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Speed Control Configuration

The SiCam Saw Track System is designed to monitor the variation that occurs in one or more bandmills. This data can be used by the control system to adjust the speed. The configuration is very flexible but the following sample is a typical

setup with two “Speed Up” and two “Slow Down” groups. Each saw that is “In Cut” will be evaluated for the speed adjustment and the worst performing saw will determine the final speed adjustment. If one saw is

performing within the “Speed Up 1” group but the other saw is performing in the “Slow Down 1” group the slow down will be sent to the PLC.

The following sample shows a typical setup but control limits and speed adjustments for each group are completely configurable.

This evaluation is done for each saw currently in the cut and is completely configurable by the user to ad as many speed up or slow down groups as desired.


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PLC to SiCam DIO Values

The following list contains a block of flags read and monitored by SiCam during the saw deflection monitoring process. The present flag and/or the photoeye will be continually monitored by SiCam to detect pieces and provide immediate

feedback. Bit Name Description Note

0 Speed Input Bit 1 8 input bits to comprise a byte to give speed input in increments of 5 fpm

Least Significant Bit

1 Speed Input Bit 2

2 Speed Input Bit 3

3 Speed Input Bit 4

4 Speed Input Bit 5

5 Speed Input Bit 6

6 Speed Input Bit 7

7 Speed Input Bit 8 Most Significant Bit

8 Speed Change Acknowledge

9 Pre-Cut Photo eye Photoeye before Saw(s) blocked

10 Mid Cut Photo eye Photoeye between Saws blocked

Quad Only

11 Post Cut Photo eye Photoeye after Saw(s) blocked

12 Saw 1 Used Saw 1 Cutting for the current piece



Quad Only


Quad Only

*This data can be encoded into several bytes to provide a streamline read from the Sawtrack system.

SiCam to PLC DIO Values

Finally the SiCam system can output a block of information for speed control or alarming. These values should be monitored by the PLC control to make speed modifications throughout the cut. Alarms can be configured to provide immediate

feedback to mill staff.

Bit Name Description Note

16 Heartbeat Heartbeat alternates every second

17 Speed Change Bit 1 4 Bits gives 15 possible values for speed change

LSB

18 Speed Change Bit 2

19 Speed Change Bit 3

20 Speed Change Bit 4 MSB

21 Data Ready

Documents

SiCam SawTrack (Saw Monitoring)SiCam provides a variety of charts and histograms to show the trending behavior of saws. This information is broken down by saws for immediate probe