AccuraCut.com

Are you looking for a quick and efficient way to cut your lumber accurately? Using state of the art electronics, this system provides an immediate indication of how far the sawblade is straying from the correct position. Continuous, real-time readout of sawblade position helps insure high quality production by alerting the operator immediatly to problems caused by....

Excessive feed speeds
Guide wear and misalignment
trash build up on wheels or blade guides
Impending blade problems such as the development of cracks or unexpected dulling
Too much strain on band sawblades and too much lead or too little on circular blades
Band wheel misalignment-both side to side and cross line
Bearing wear and excessive play

Quick Links
Pictures
Blow The Whistle On Miscut Lumber
Purchasing Information
Testimonials
Frequently Asked Questions
Installation Suggestions
Contact


AccuraCut Deluxe - (AC-50)	AccuraCut Standard - (AC-40)
Click To Enlarge	Click To Enlarge

Sensor Unit	50' Sensor Extension Cable
Click To Enlarge	Click To Enlarge

Back To Links

Blow the Whistle on Miscut Lumber

TRACK RECORD ON SAW DEVIATION

Interest in tracking saw deviation has continued to grow in the forest products industry as limited resources, expensive stumpage, and keen competition have driven mills to look for ways to increase yield and bring more dollars to the bottom line. Tracking devices or detectors can sense when a saw is deviating from the set tolerances and warn the operator, who in turn can slow the feed speed to avoid miscutting lumber. It?s a simple concept, but the benefits of such monitors can be quite substantial. There are plenty of problems that can cause a saw to deviate and a number of variables have to be evaluated before pinpointing the cause of mis-cut lumber once the monitor indicates a problem. There could be a problem in the initial setup of the mill or the sharpness of the saw itself, but generally; it?s caused by wood characteristics and varying densities of the wood being cut. Saw deviation detectors provide real-time feedback of the exact position of the blade relative to the expected position. Any deflection of the blade, whether caused by too high a feed speed, knots, frozen lumber, dull or damaged blade, trash between the blade and guide block, or simple guide wear will instantly be detected by the monitor allowing the operator to correct the situation before lumber is mis-cut or the saw is damaged. Equally important, by monitoring the blade position and ruling out blade deviation as the source of miscut lumber, it becomes much easier to effectively zero in on other issues, such as track misalignment or head blocks out of adjustment, that might be causing production problems. All deviation detectors include a sensor that is placed next to the bandsaw guide. These sensors actually ?feel? where the saw is running in the cut. The advantage of real-time information is largely what makes the increased production possible. With a real-time look at what the blade is doing, operators can actually see right away if they?ve cut irregular lumber, versus finding out when they measure the lumber later on.

DETECTOR DETAILS

Our monitor, which can measure deviations as small as a few thousandths of an inch, uses a proximity sensor, a controller display unit, and a data cable that connects the two together, to indicate deviation and sometimes vibration when it actually occurs in the saw. The ?real-time? aspect of the process discourages unplanned downtime. You don?t have to wait until you get downstream and measure the lumber to see you have a problem. We can see it while it?s happening-that?s the real-time aspect of the process. The AC-50 offers a digital read-out of blade from proper position, and a digital and an analog output, enabling communication with other equipment.

CONSIDERING A MONITOR?

The monitors can serve in a teaching capacity for first-time operators. If you?ve got a new guy in the sawyers cab, it helps him know how much wood he can push through, and it helps him learn tolerances. It?s kind of like a speedometer in that the deviator becomes a good way to gauge how fast you can go and stay within tolerances. The Sawblade Deviation Detector provides real time feedback from the proximity sensor, with a visual display that indicates varying degrees of deflection. The display box is set in the operator?s line of sight, and contains a series of light bulbs. Green lights indicate a safe range, yellow lights warn of deviation out of good operating range, and red lights indicate deviation beyond acceptable tolerances. Many industry experts say monitors are tools that give operators and filer?s insight on saw behavior as well as assuring the correct operation of the equipment. Every operation, even the most sophisticated sawmill equipment with the very best in people, as the day goes on, will produce less than the best lumber. The payback period is relatively quick. The SDD-40 model often has a payback in little more than 60 days. A system of lights on the SDD-40 display box indicates the saw?s behavior; a safe operating range is reflected by three green lights in the center of the display; a slight deviation is reflected by two yellow lights, which may also indicate the blade is getting dull; red lights and the sound of an alarm to warn the operator of an unsafe deviation. It lets you know exactly how fast you can travel through the cut without ?getting stopped? for speeding. On the other hand if you?ve been traveling ?45 and the conditions are such that you could have been traveling ?55?, the deviator lets you know that you are well within limits, go ahead -go faster! With only 2-4 hours installation time, the Sawblade Deviation Detector can be purchased for approximately $2,850. The Model SDD-40 comes complete with controller/display module, sensor unit, and cabling and operates from a standard 110V outlet. It offers an adjustable setting for sensitivity and allows remote centering of signal for display. We are selling one of the lower-priced units on the market. It is our belief that the maximum benefit is obtained from Deviation Detection units when they are rugged, simple to install, intuitive to operate, and inexpensive enough to use on every saw in the mill. The Deviation Detector can help sort out problems with guide wear or set works performance. It can help determine proper feed speeds and aid in calculating the optimum time between blade sharpening. Most importantly, the Deviation Detector allows the sawyer to push his equipment to the limit in pursuit of maximum production with full confidence that he?s not exceeding the capability of the blade.

Back To Links

Purchasing Information

Complete Systems

AccuraCut Deluxe - (AC-50)
Includes: 1 Controller/Display Unit,1 Sensor Unit w/ universal mount, and 50ft. of Sensor Cable. 2-year warranty	$4,250.00
AccuraCut Standard System - (AC-40)
Includes: 1 Controller/Display Unit, 1 Sensor Unit w/ universal mount, and 50ft. of Sensor Cable. 2-year warranty	$3,390.00

Optional Accessories

Extra Sensor Unit
To replace original sensor supplied with system.	$420.00
Remote Light Set
Mimics the lights on the main unit.	$750
Cable for the Remote Light Set	$2/ft.

Back To Links

Testimonials

...We cut a lot of White Oak, as the safety director I like the fact that the deviator tells our saywer when they are over feeding our 12" boards. Each blade costs us $800, so every blade we keep from being wrecked saves us a lot of money...

-Craig Loner
Safety Director
Clendenin Lumber
Greenwood, SC.

...the Deviation Detector tells our sawyers instantly if the saw is running straight. They've been on our 56" headsaw and McDonough Line Bar Resaw for over 9 years. There's no telling how much miscut lumber they've saved us and that means more profit and happier customers...

-Elroy Bontrager
Head Sawfiler for Indiana Wood Products

Back To Links

Frequently Asked Questions

1. What exactly do you mean by "Sawblade Deviation"?

When either a bandsaw or circular saw is properly set up and properly operated, the blade will consistently run in exactly the same position. If the blade moves away from that set position, that is called blade deviation. The Sawblade Deviation Detector (also refered to as the Accura-Cut) will help you spot that deviation from expected position as the cut is occurring so that you can take corrective action immediately.

1. How does the unit know where the blade is? Does it actually touch the blade?

No part of the unit comes in direct contact with the blade. The system measures the position of the blade by noting its effect on a pulsating electromagnetic field. This was it "sees" only the blade itself and in not affected by word chips, cutting fluid or any other non-metalic substance between the blade and the detector.

3. What does the system consist of? What comes with the complete unit?

There are three main components to the complete system: the sensor, which is a small cylindrical object mounted near the blade; a controller display unit which is typically mounted in the sawer's cab; and a data cable which connects the other two components together. We also provide a small bracket for mounting the sensor and (optionally) any extra cable needed to extend the distance from the sensor to the controller/display unit.

4. Why is it so important to know if the position of the blade is deviating?

Two words; quality and efficiency. In order to cut lumber of high quality and consistent thickness, it is important that the cutting blade stay exactly centered at its optimum position. If a bandmill blade begins to pull to the side, it will produce uneven lumber thickness - resulting in scrap material. In a worst case, if the deviation is great enough, the blade can come in contact with the saw structure resulting in expensive damage. If circular saw blades deviate excessively, the result can be increased temperature and rapid loss of blade temper and sharpness -- again, an expensive problem. It is important to catch the blade deviation early while there is still time to avoid blade damage or lumber waste. On the other hand, if the operator is not running at the maximum practical feed speed, the full capacity of the machine is not being used. Also, too low a feed speed can result in the production of very fine sawdust which builds up in the kerf causing heating and premature wear to the blade. The Accura Cut acts as an accurate, straight forward speedometer - helping the operator to find that right combination of throughput and quality.

5. What kind of conditions will cause blade deviation?

The most common cause of blade deviation is improper feed speed - feeding lumber into the saw at a rate higher than the blade can handle forces the blade out of position. Damage to the blade (caused perhaps by hitting trash in the wood) can result in an uneven set on the blade teeth causing the blade to pull to the side on each cut. Cutting frozen or heavily knotted wood requires reduced feed speeds to insure a proper cut. Worn or damaged blade guides can cause the blade position to shift. The important thing is that no matter what the cause, if the blade's position changes, that saw operator will see that change immediately on the operator's monitoring display panel.

6. What exactly is that output? What will the operator see?

The controller display unit, which is normally mounted in the saw operator?s line of sight within the saw cab, is equipped with a row of 9 colored, highly visible lights. The three center lights are green indication the normal operating range. Four more lights, two on either side of the green lights, are orange indicating significant levels of deviation. On each end of the row are single red lights indicating maximum deviation. Only one light is illuminated at any time. The illuminated light?s position with respect to the center indicates the direction and degree of blade deviation that is occurring. The unit contains an audible alarm which can be se to go off whenever maximum deviation occurs. That same signal can be fed to an optional external relay which can be used to trigger a strobe light, external alarm, or shut-down switch.

7. Can the deviation output be recorded or remotely monitored?

Yes. An optional Remote Light Set can be connected to a special output port on the side of the unit. These lights can be placed in the maintenance room, filing room, or other location and will exactly mimic the main lights on the controller display unit. There is also another output port on the Accura Cut which provides an analog signal proportional to deviation which can be record on an oscilloscope or strip chart recorder for later analysis.

8. Can that output signal be used to automatically control feed speed?

Automatic control of the carriage would require special interface electronics which depend on the type of carriage mechanism and speed controller being used. Call for pricing.

9. How difficult is it to install the Sawblade Deviation Detector? Will I need help?

In most all cases, installation of the Accura Cut is very straightforward and can be handled by your own in-house maintenance personnel. You simply mount the sensor near the blade either just below the upper guide or just above the lower guide; install the controller display unit in the sawyer?s cab and connect it to 110V input power. You then connect the two components using the cable provided. Onsite installation is available, call to schedule Millright service.

10. Will this system work for any width of blade?

Because of the size of the sensor itself, it isn?t recommended for blades narrower than 1? in width. However, wider blades should present no problem as long as the sensor is properly mounted.

11. Do I mount the sensor in the center of the blade or near the edge? What do I do if I have a double cut bandsaw in both directions?

Since it is the movement of the leading edge of the blade which is most critical, normally the sensor is mounted just behind the gullet and about ?? away from the surface of the blade. However, for double cut applications, mount the sensor in the center of the blade and to get useful information. For optimum performance on wide blades in a double cut application, we recommend using two systems with a detector mounted on each edge of the blade. This will give uncompromised information about the performance of the blade in each direction and allow independent adjustment of the system parameters for each direction of cut.

12. What sort of set-up adjustments are required?

The body of the sensor unit is threaded and is secured by a large nut on either side of the mounting bracket. While the blade is stationary, you attach the sensor to the bracket and adjust its position with the nuts until only the center green light is illuminated on the display unit. Once the saw is in operation, you can fine tune the centering of the lights (to compensate for guide wear, etc.) through an electronic control on the face of the controller unit. You can also adjust the response rate (how quickly the lights react to changes) through another control knob on the unit. This gives you the option to look at every tiny flicker in the blade?s position or to filter out the high frequency effects and just concentrate on the longer term movement of the blade.

13. Just how sensitive is the unit anyway? What is the smallest deviation I can detect.?

The unit itself is very sensitive and can measure deviations of only a few thousandths of an inch. However, the actual movement of the blade at the point of cut will depend on the geometry of the installation since the sensor will always be some distance away from the point of cut. How far the sensor is from the cut and how far it is from the blade guide will determine the relative deviation being measure. Since this is different for every installation, we recommend you measure this as part of the set-up process. While the saw is stationary and after the sensor has been installed and adjusted, simply deflect the blade at a position representing the point of cut and measure the amount of deflection while noting the response of the lights over the full range. In order to provide the maximum useful range, the output is electronically adjusted to give more response in the center green light region where it?s most critical. The amount of deviation represented be each light grows greater as you move further our toward the limit on each side.

Typical Blade Deflection Curve

Back To Links

Installation Suggestions

Price

1st unit $500 + travel expenses. $350 for additional units.

Need the installation done professionally? On Time Construction would be happy to give you a hand.

Back To Links

Contact

For any more information please contact us!

Jon Yoder
Phone: 574-238-5199
E-mail: jyoder@accuracut.com

Back To Links

Website Design by Vortex Web Solutions