why should you care? - optisaw...#1 : log/tree identification vision need - automatic tree or log...

By Eric Dunn June 5th, 2018

SM2: What is Smart and Agile Manufacturing?

Why should you care?

Optisaw 2018

Partners

© 2017 FPInnovations. All rights reserved. Copying and redistribution prohibited. ® FPInnovations, its marks and logos are trademarks of FPInnovations.

§  Non for profit Research & Innovation institute ▫  75M$ in R&D and Innovation activities

▫  425 employees

▫  175 member companies (Canada only)

▫  Associated with Universities in research

▫  Laboratories

§  Majors Programs of Innovation ▫  Forest Operations

▫  Wood Products

▫  Pulp & Paper, Packaging and sanitary

▫  Bioproducts & Bioenergy

FPInnovations

Québec (QC)

Vancouver (BC)

Montréal (QC)

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Challenges of the forest industry sector

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§  Mill equipment are partially/not interconnected ▫  (loss of information, duplication of functions) ▫  Value chain elements (FàC) still in silos

§  Skilled manpower shortage §  Sawmill Technologies not attractive to tech

people §  Traditional tech deployment based solely on

traditional performance indicators offers modest ROI (eg: productivity, output-material)

§  Strong desire to diversify products and co-products

§  Operational Excellence varies considerably between CO, within mills of the same COS, shifts and even a department


SM2 Mission: In sync with 21st Century Needs

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§  Stimulate the growth and prosperity of the Canadian processing sector by: ▫  Reducing dependency on co-products

income; ▫  Enhancing value & recovery and productivity

via breakthrough technologies; ▫  Enabling SMART and AGILE manufacturing

solution for the 21st century business needs and market demands ;

▫  Accelerating research to commercialization by facilitating partnerships between industry, government and academia.


SM2 Outcome: A Smart & Flexible Manufacturing Toolbox

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© 2017 FPInnovations. All rights reserved. Copying and redistribution prohibited. ® FPInnovations, its marks and logos are trademarks of FPInnovations. 6

Sawfiling room

Applications:

Advanced Intelligent Vision (7 applications) Smart Platform (5 applications) New technologies (3 applications)

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A

B

CC

D

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Advanced Intelligent Vision and Applications #1 : LOG/TREE IDENTIFICATION VISION

▫ Need -  Automatic Tree or Log

species ID using bark

▫ Area of application -  Debarker and bucking

control

▫ Benefits -  Yield recovery improvment

debarker -  Productivity Gain debarker -  Production costs reduction

Deep Learning Algorithm

FIR


▫ Need -  Capturing more value from

large valued logs

▫ Area of application -  Log sorting by 3D shape &

internal quality -  Log breakdown at headrig

line

▫ Benefits -  Improve grade recovery

FPI CT Feature Detection

FPI CT concept

Advanced Intelligent Vision and Applications #2: INTERNAL LOG DEFECT FEATURES IDENTIFICATION


Advanced Intelligent Vision and Applications # 4/5 : AUTOMATED LUMBER SPECIES ID (Green & Dry conditions)

PIR Sensor

▫ Need -  Provide a 95% accurate species

identification system in lumber (sawmill and planer mill)

▫ Area of application -  Green sorting of lumber (SPF) -  Sorting for niche market/value

(Planer)

▫ Benefits -  Improved drying productivity -  Improved grade and y ie ld

recovery


Smart Platform A : REAL TIME ADAPTIVE CONTROL FOR DEBARKING

RT Controller

▫ Need -  Automatic measurements of

logs attributes (temp, MC, Species)

• Control in real time debarker’s operational parameters from infeed information

▫ Benefits -  Improve LRF -  Increase speed -  Reduce costs


Smart Platform B : REAL TIME ADAPTIVE CONTROL FOR LOG TURNING

▫ Need -  Create Smart Log Turner with auto

diagnostic; -  Combine Advanced Vision System

with AI (Machine Learning, data science,…) for Real Time Process Control

-  First step for future application on other machine-center

▫ Benefits -  Improve volume and value

recovery -  Plus 500K$ annually or 1.75$/m3


Smart Platform C : AUTOMATED SAW FILING ROOM

▫  Need -  Improve Operational Excellence in sawfiling

room -  Interconnectivity between smart machines,

tooling and material (tracking) •  Integrate technology like Guide temperature

sensor to track the saw history. -  Mitigate shortage of skilled sawfilers -  Increase feed speeds

▫  Benefits -  Reduce saw kerfs -  Improve Lumber recovery -  Reduce production costs


Smart Platform D : REAL TIME ADAPTIVE CONTROL FOR PLANER SETTINGS

▫ Needs -  Self adjust cuttings tools, bed,

etc on a continuous basis •  Using data from the

incoming lumber, tooling quality and outcoming lumber quality

-  Combine AVS with AI (Machine Learning, data science,…) for RT planer control

▫ Benefits -  Improve grade recovery (7%) -  Improved value gains $4.45/Mbf

Courtesy of Les Produits Gilbert


New technologies 1 : NEW GENERATION OF SAWBLADES

▫ Need -  Narrower kerfs target 0.080 in, feed speed > 1,000

fpm -  Increased durability (2x)

▫ Benefits -  1,25$/MBF/0.01" reduction -  $375,000, (100MMbf mill) -  Improved Lumber Recovery, %2x4 ↑, predominant

length -  Reduced chips, reduced sawdust -  Lower production costs


New technologies 2 : ULTRAFAST LUMBER DRYING

▫  Needs -  Match the drying productivity to the sawmill productivity -  Adapt process to mixed lumber thickness, width and length -  Eliminate the sorting line -  Dry at different final MC specifications and quality

requirements depending on product end-use

▫  Benefits -  Reduce production costs -  Increase mill flexibility and agility (pull -  approach)

▫  Schedules & deliverables -  Summer 2020 -  Small lab demonstration


New technologies 3 : COMMERCIAL DEMO OF CONTINUOUS PRECISION RADIO FREQUENCY DRYING (Spruce and Fir)

▫  Needs -  Match the drying productivity to the sawmill

productivity -  Adapt process to mixed lumber thickness, width

and length -  Eliminate the sorting line -  Dry at different final MC specifications and quality

requirements depending on product end-use

▫  Benefits -  Reduce production costs -  Increase mill flexibility and agility (pull approach)

▫  Schedules & deliverables -  Summer 2018 -  Commercial demonstation of a Continous precision

RF drying system


Closing Remarks

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§  Companies react faster to market changes by producing smaller, more profitable production runs or batches.

§  New generations of Advanced Vision systems, New technologies,

PLUS Smarter machines with Artificial Intelligence, Machine and Deep Learning for real time adaptive control EQUAL Manufacturing of the future adapted to Business needs and market demands of the 21st

century for SMART and AGILE manufacturing solutions.

§  This century will reward the Gazelles - companies that will be smart, fast, and flexible.

§  You want to participate, dont hesitate to call us

www.fpinnovations.ca

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Thank you For additional information: Serge Constantineau ing.f., MSc Directeur de l’initiative SM2

FPInnovations

[email protected] 514 782-4566

why should you care? - optisaw...#1 : log/tree identification vision need - automatic tree or log...

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