Formulae
Formulae
Formula Sheet Plan View Measurements 1 Typical layout for Horizontal Edgers 2
Saw and Tooth Shape Setting up the wire Wire Mount and winch jigs 3
d Circular saw diameter or bandmill wheel dia.(inch)
P Tooth pitch (inch) Positioning the wire from the edger arbour Telescopic Sensing Head 4
n Number of teeth 5
Measuring From The Wire
k Kerf
h Thickness of saw plate Infeed Line Bar Magnetic based Sensing Head 6
s Side clearance (inch)
sMIN Minimum recommended side clearance (inch) Edger internal line bars
a Gullet area (square inch)
Elevation Measurements 7
23
Measuring Instruments & Tools c=
♦ Machine Alignment
♦ Saw Filing
Thin Kerf Technologies is your best source for instruments and practical solutions for sawing,
feeding and chipping problems. We have the mill experience, the professional skills, training, and
can access the latest developments in sawing and chipping technology. TKT provides your people
with training, advice, and instruments to improve the operation of your mill.
This catalogue describes the instruments needed to align Edger systems. It also outlines the
principles of alignment using these instruments.
These instruments, and the procedures for using them were developed during TKT’s consulting work
and from the feedback of our customers.
Machine alignment requires the proper you can’t cut it STRAIGHT s = k-h or k=h+2xs
tools so that it can be done accurately 2
and quickly. The benefits of good
alignment are: E = CxkxfxD
144
• Correctly sized lumber
• Less down-time due to jamming
• Reduced maintenance costs because all parts are carrying their designed load.
• Fewer unscheduled saw changes For Circular Saws Only
• Faster trouble-shooting
P = 3.14 x d or n = 3.14 x d
To achieve these benefits, Thin Kerf Technologies promotes the concept of Maintenance for Accuracy, in P P
the same way that Preventive Maintenance ensures mechanical reliability.
To increase the speed of trouble-shooting, we developed the BoardRunner - an advanced Q.C. and b = 12 x f or f = bxnxN
diagnostic tool for measuring and analyzing boards. This product is now marketed by Simonds Industries Nxn 12
Inc. The information from the BoardRunner pin-points the exact cause of mis-manufactured lumber - no
guessing.
24
Plan View Measurements
Setting up the Tight Wire
New Product
The first step is to run a wire through the system from the start of the infeed section through to the end of
the outfeed of the outfeed section of the edger. This wire should be tight and roughly level. Ideally, the wire Saw Centering Adaptor
should run from a winch for quick installation, but a come-a-long or strap winch can also be used. Centers saws accurately for top, face and side grinding
Hanging weights to tension the wire is awkward and dangerous. If there is a line bar section on the infeed,
the wire should positioned by eye about about 6 - 8 inches from the face, and about 4 - 6 inches above the of splined circular saws
bed rolls.
Tip Use downrigger wire (150 lb. test) rather than piano wire.
It does not kink like piano wire and it lays flat when there is no
tension.
Use adjustable supports, as shown on page 3, to locate the wire. Avoid using a notch filed into a bar
because there will inevitably be other notches, and no one will remember which is correct. Secondly, the
adjustable support is designed for making quick and accurate positioning of the wire.
These supports should be bolted and dowel pinned to a substantial frame that, ideally, connects to the
foundation. Also, the wire set up will be less sensitive to movement of the supports over time if these
points are as far apart as possible. With this set of tools consisting of the supports located by dowel pins,
and a winch, the wire should be accurately in place within 20 minutes.
Set the Telescopic Sensing Head on the arbour and rotate the arbour so that the sensing head pointer can
be adjusted to touch the wire. Rotate the arbour and adjust the pointer until the LED just flickers on one
side of the arc. Set the dial indicator to zero. Rotate the arbour until the pointer once again passes the
wire. Adjust the pointer and note the change in dial indicator reading. See page 4 for illustration
Measure the arc distance along the wire that the pointer makes at it’s two contact points.
Measure the distance between the two wire support jigs ( the total length of the wire).
Tip Make sure that the edger door is firmly closed and that the arbour is in
it’s normal operating location when taking these measurements.
1 22
Maintenance for Accuracy
Method
This manual is developed using the information gathered
from the “Machine Audit” and it defines:
Objectives
To set up work sheets, schedules and tolerances that are realistic and achievable to keep the machine
running for optimum cutting acuracy and performance level.
3 20
MEASURING TO THE WIRE Consulting Services
Machine Center Audit
Checking the Edger Bed Rolls
TKT provides specialized consulting services dedicated to improving machine center performance. We
Reduce the Telescopic Sensing Head arm length until it will reach the wire when mounted on the edger believe that before any improvements can be made to an existing system, there has to be a meaningful
bed rolls. Set the pointer until it just touches the wire and the LED just flickers. Set the dial indicator to analysis done about how good a job the machine center is doing at present. Quality and cutting accuracy has
zero. Rotate the bed roll until the pointer makes it’s second contact with the wire on the opposite side of to be related to the existing maintenance and alignment procedures. To do this TKT provides a Machine
the arc of contact. Adjust the pointer until the LED just flickers. Make a note of the new dial indicator Center Audit consulting service as follows.
reading on a work sheet. Also make a note of the swing distance. Complete this procedure for all bed rolls
. Method
Press Roll Frames Establish existing:
Attach the Telescopic Sensing Head to the press rolls and complete the same procedure as for the bed Alignment
rolls. Make sure that the wire is high enough off the bed rolls to allow the sensing head dial indicator to Saw preparation
clear. Saw specifications
Feed system functions
Check all press roll frames for cracked and broken joints. Check cylinder mounts and clevises. Check press Performance of setworks
roll frame bearings for end play before using the sensing head. Check for press roll frame rigidity by Machine controls
placing a 4" x 4" on one side of the press roll as shown below. Activate the press roll cylinder and check Feeds and speed analysis
the level of the press roll using the Cradle Level on page 9 before and after the placement of the block. 44 squares in gullet
Condition of the wood
Grid is 6 squares per inch
Area = 44/36 = 1.22 sq. in.
Recommend:
Priority of changes
Cylinder Force
Objectives
Press Roll
Once it has been clearly identified how well the
Wooden Block machine operates in its present condition, plans can
Test Both Sides be developed to:
Tooth Inspector
5 18
Saw Damage
Elevation Measurements
Gullet cracks are usually caused by over filling the gullets. Check the saw specifications using TKT’s
The Hydro-Level can be used to measure elevations relative to a chosen datum. The unit consists of a base, SawSel.
the hose, and a vial. The operating principle of the Hydro-Level is that the elevation of the fluid at each
end of the hose are equal. It can be used to measure elevations of the vertical arbor saw guide support pads. Blue spots and burn marks on saws can be caused by any of the following :
We recommend that the machine is level, and does not run up or down hill. This allows you to use a 1. Operating the saw at or close to one of it’s natural frequencies. Check the saw specs
machinist’s level when installing or checking a part. using SawSel
The following sections describe how to measure the elevation of some of the more important components. 2. Bent Guide Post or Guide Bar causing the guides to be out of alignment with the feed system
The elevation and straightness of all components that support the piece while it is being machined must be and the saw arbour. Check the straightness of these components using a machinist’s level,
measured - from the infeed rollcase through to the end of the outfeed rollcase. Sine Bar, or the Telescopic Sensing Head. To use this jig to check this parallelism of the
guide bar to the arbour, first attach the jig to the arbour. Rotate the sensing head pointer 90º
such that it will point to the guide bar. Adjust the sensing head pointer until it just contacts the
guide post. Set the dial to zero and rotate the arbour to make sure the pointer just contacts the
Important guide bar and the LED just flickers. Take readings across the width of the edger to check for
Any high points or kinks in the feed will affect lumber size accuracy. parallelism to the arbour.
There will also be more down-time because: 3. Bent saw arbour. Check the straightness of the arbour by taking a series of level readings
• the wood jams or along the length of the arbour. Make a mark on the arbour where these readings are taken.
• the saws are damaged by the wood leaning on them. Rotate the arbour 180 º and take the readings again at the same locations as before.
If the readings are equal, then the arbour is straight. If the readings are different, then the
the arbour is bent.
Edger Infeed System
4. Incorrectly machined babbitt. Check the flatness of the machined babbitt using a granite block
Before checking the level of these rolls, check each individual roll for roundness, wear, and a depth dial indicator.
and for bearing end play.
1. Set up the Hydro-Level base in a convenient location so that all the rolls in the complete 5. Guide spacers with high spots, nicks and burrs. Check these also on the granite block for
system can be accessed. flatness.
2. Place a piece of flat bar such that it will span two rolls and position the vial directly over the first 6. Guide to saw plate clearances are too tight.
roll to be recorded.
7. Saw guide lubrication system not operating correctly.
3. Repeat this procedure for all the rolls in the system. Plot the results to get a complete
profile of the machine’s independent components. 8. For vertical edgers, the bottom guide support pad may not be parallel to the guide bar.
Check these relative elevations using the Hydro Level and a machinists level.
9. For vertical edgers, the saw arbour may not be parallel to the guide post. Check this by using
Tip: The elevation of the infeed system and outfeed system bed rolls should be approximately the Sine Bar.
1/16" below the edger bed rolls. This will ensure that once the piece has entered the edger, it will not 10. For vertical edgers, the feed rolls may not be parallel to the guide post. Check this by using
be influenced by either of these systems. the Sine Bar.
7 16
Sine Bar Quick Checks and Fixtures
The Sine Bar is a level mounted on a square so that the slope of a vertical surface can be measured. Rather
than using the divisions on a vial to measure deviations from plumb, a micrometer adjustment is used to set TKT supplies custom made straight edges. These incorporate a linear bearing that is perfectly aligned
the bubble to zero. The amount of off-plumb over a 5 inch distance is read directly off the micrometer. with the edge of the straight edge. Place this straight edge against the line bar so that the end of the
Measurements should be recorded in units of inches per 5 inches. straight edge is cantilevered into the edger far enough to reach the guides as shown in the diagram .
Use the dial indicator to check for parallelism of the guides to the straight edge.
This instrument can be used to check the plumb of the
Saw arbours Using the infeed line bar as a datum, place the straight edge against the line bar as discussed above,
Feed Rolls (vertical and horizontal) and check for lead in the edger bed rolls by using the Telescopic Sensing Head attached to the bed
Line bars roll. Touch the straight edge with the pointer and set the dial to zero. Rotate the roll until the pointer
Guide Posts (shifting saw edgers) touches the straight edge on the opposite side of the arc of contact. Adjust the pointer until it touched
Any vertical or horizontal surface the straight edge and make a note of the difference on a work sheet.
One degree corresponds to 0.087 in. on the Sine Bar micrometer Another use of the straight edge is to check for the level of the edger bed rolls relative to those of the
infeed and outfeed systems. Place the straight edge on the edger bed rolls with the press rolls in the up
Some of the difficulties that could be encountered when measuring level or plumb: position and cantilever the end out over the infeed rollcase. Check to see if the top of the rolls in the
in feed rollcase are below those of the edger. Do the same for the edger out feed rolls.
1. Measuring the level or plumb of press roll faces because of their knurling or coleman inserts.
The new Cradle Level makes it easier for doing this job as the cradle self centers on the roll, and the
magnets lock it into place for easy hands off recording. As these surfaces are difficult to get a one
time true reading, change the location of the cradle on the roll and take two or three different L IN E B A R
readings. ARBOUR
8 F T S T R A IG H T E D G E
2. The shaft of a bed roll might be bent. Check by measuring the tilt at points 180º apart on the roll. If
the readings are equal, then the shaft is straight. If the readings are different, then the shaft is bent.
Check at both ends of the roll.
3. The face of a roll or line bar may not be straight. Take readings where most of the contact with the
wood takes place. Make a note of the wear on a work sheet.
GUIDES
Use the Sine Bar to make quick checks for all plumb and level components and surfaces.
9 14
Saw Guides
It is critical that the saw guides are correctly aligned to the feed system. To check this, use the
Edger Guide Alignment Jig.
This jig is designed to to create a perfect right angle between the machined V blocks in the base,
and the rail and linear bearing. Attach this jig to the arbour and take readings along the length
of the guide using the linear bearing with the guide clamped in position. Rotate the arbour and
take plumb measurements down the depth of the guide.
Attach an extension bar to the linear bearing mounting plate and insert the dial indicator. The
extension bar allows the dial indicator to reach the vertical shifter guide posts in shifting saw
edgers. Take readings across the post width without the guide attached to it Use a Sine Bar on
the same face to check for plumb.
The guides and guide spacers should be checked for flatness using a granite block, and for
thickness consistency using dial callipers.
11 12
Vertical Edgers: Level, Plumb, Alignment and Elevation Table
For vertical edgers mounted in line in a Chip-N-Saw or a Canter, see the TKT’s “Alignment Procedures Item Level Plumb Alignment Elevation
and Instruments For Chip-N-Saws and Canter Lines”
Infeed system bed rolls Cradle Level or Telescopic Sensing Head Hydro-Level, Strtaight
These notes are for the vertical edgers systems which are a complete stand alone machine center where Sine Bar Edge & Machinist’s
the edger is either a single or double arbour type with in feed and out feed banks of bed and press rolls as Level
shown typically below Infeed system crowder Cradle Level or
rolls Sine Bar
Edger Bed Rolls Cradle Level or Telescopic Sensing Head Hydro-Level, Straight
PRESS ROLLS GUIDES Sine Bar Edge & Machinist’s
Level
Edger Press Rolls Cradle Level or Short Sensing Head
OUTFEED INFEED Sine Bar
13 10
TROUBLE-SHOOTING GUIDE
Sawn Surfaces
Snaking
Snaky lumber is usually caused by overheated saws. Check the Gullet Feed Index (see formula page 24), Hydro Level System
the side clearances, the guide clearances and the lubrication system.
Bevel or Mismatch
Usually caused by saws deflecting in the cut due to incorrect saw specifications or feed speeds (see SawSel
on page 22 to check the Saw Load Index). Check guides and spacers for flatness and parallelism.
Check kerf widths and saw plate thickness for consistency.
Hydro Level
EXAMPLE If the saw guides are are out of alignment with the feed being used to
system by 0.006" over the length of the saw guide (say 6") the piece will be
back cutting if the saw is, say 22" in diameter, and has a kerf to plate side check bed roll
clearances of 0.015" per side. elevations
Rough surfaces can also be caused by the bite/tooth being too large. When the bite/tooth exceeds 0.055”,
sawn surfaces get rough to the touch.
Tip If the cant surfaces are parallel, the problem is usually the edger press rolls.
Machinist’s Level
Only a precision quality machinist’s level should be used for alignment work. The lines on the vials are
Remove the saws and guides from the edger. Raise the press rolls. Run pieces through calibrated for direct reading of the slope. From the slope the amount of shim needed to level a part can be
and see if they pull away from the line bar. If they do, the problem usually is related to quickly calculated.
the infeed section feed rolls being worn and dished. If the piece doesn't pull away, bring
Cradle Level
down one press roll at a time and run pieces through the edger. This way, when a piece This instrument incorporates a machinist’s level into a self-centering frame. It is designed to allow level
pulls away, you have identified the problem roll. and vertical plumb measurements to be taken for rolls and arbours.
15 8
Measuring Lumber
Tip : Check arbour and bed roll bearings for end play before using the Telescope Sensing
Regular Quality Control programs give you adequate information about the average thickness of the wood. Head. If there is excessive end play in these bearings, the readings taken with the
As a maximum of six measurements per edge are taken, it is not possible to get a true picture of what is sensing head may be inaccurate. Check all rolls for roundness using a magnetic
actually happening to the wood as it passes through the machine. based dial indicator.
BoardRunner can take as many as 256 measurements per edge at a walking pace. The display is on board
the instrument and gives a picture of the thickness profile of the wood. Infeed System Line Bar
Wherever a piece changes thickness, either it has moved in the machine, or the saws or chipping heads
Check the run out of the line bar relative to the wire using the sensing head. First, remove the sensing
have moved. If there is any consistency in these changes in thickness, the BoardRunner will identify
head from the telescopic frame and add a ground wire. Attach the sensing head to a magnetic base as
exactly where the change takes place.
shown in the picture below. Take measurements along the length of the line bar to check for
parallelism to the wire.
Use the same procedures for checking any line bars mounted inside the edger.
BOARDRUNNER
The BoardRunner not only tells you that there is a problem with lumber sizes....
.......it tells you what caused the problem so you can fix it
Checking a line bar
17 6
Team Training
As machines get more complex, it takes teams of individuals working together to get the best
performance from a machine center. A typical machine center will need input from an alignment Telescopic Sensing
specialist, millwright, electrician, saw filer, Q.C. personnel, and a machine operator. Head set up on
Each person in the team must understand how different team members’ input effects the performance of arbour
a machine center. TKT provides “In House” seminars covering the following issues:
Quality Control
How to read the wood and measure accuracy performance.
If the decision is made to move the wire, the folllowing example gives the distance one end of the wire
Saw Preparation and Performance has to be moved to make the perfect right angle to the saw arbour
Understanding the basics of saw preparation and saw selection.
To move the wire quickly, set digital calipers from the slotted nut to a fixed point. Zero the calipers.
Alignment Move the slotted nut and watch the calipers until they are at the proper setting.
Now that the wire has been moved, recheck the new location by using the telescopic sensing head on
Understanding the issues of alignment and how to use the instruments the arbour once again. Move the wire again if necessary until the sensing head dial reads zero at both
arc point locations.
Example:
19 4
Saw Selection Software
If the machine alignment is good and the machine feeds the wood straight, there is the possibility of
reducing kerf or increasing feed speeds, or both. SawSel is designed to make circular saw specification
changes relative to feed speeds, depths of cut and wood species. Just insert the disk and follow the on screen
instructions.
SawSel is......
a tool for sawfilers, maintenance managers, quality control personnel and production supervisors for making decisions about saw
design and operations. SawSel includes the tried-and-true rules of circular saw design and incorporates the latest developments in
sawing technology. SawSel is unique. It uses a computer model of the blade to estimate blade stiffness, which is the most important
factor affecting cutting accuracy.
WIRE
• Load Index (L.I.) - A measure of sawing accuracy that considers blade stiffness and cutting forces.
• Critical Speed - The maximum speed to run the saw before vibration instability occurs.
21 2
INDEX Pg Diagrams & Photo’s Pg
Formula Sheet Plan View Measurements 1 Typical layout for Horizontal Edgers 2
Saw and Tooth Shape Setting up the wire Wire Mount and winch jigs 3
d Circular saw diameter or bandmill wheel dia.(inch)
P Tooth pitch (inch) Positioning the wire from the edger arbour Telescopic Sensing Head 4
n Number of teeth 5
Measuring From The Wire
k Kerf
h Thickness of saw plate Infeed Line Bar Magnetic based Sensing Head 6
s Side clearance (inch)
sMIN Minimum recommended side clearance (inch) Edger internal line bars
a Gullet area (square inch)
Elevation Measurements 7
23
• Bandsaw Saw Selection Software (BandSel) Thin Kerf Technologies Inc.
• Saw Centering Adaptors
• Chip-N-Saw and Canter Alignment
Equipment(See Alignment Procedures and
TKT Other
Instruments for Chip-N-Saws & Canter Lines)
• Special Purpose Straight Edges
Products
ALIGNMENT PROCEDURES AND Publication # 2
• Tooth Inspector
• Saw Lubrication Systems INSTRUMENTS FOR EDGERS
Sales Agents and Distributers in Canada, USA, Australia and New Zealand