New panel saws emphasize speed & accuracy.

Panel sizing operations are big benefactors of continued improvements in applie electronics and computer control technologies.

The drive to customize wood products, especially in high-volume manufacturing environments, is being met head on by the ability to further automatize the production process. This latter trend is readily apparent in the area of panel saw technology, where the most recent developments combine more efficient computer controls and related graphics with faster feed speeds and positioning device motors.

Panel saws, as much as any other piece of equipment, are caught up in the computer revolution that is sweeping through all levels of the woodworking industry. According to the consensus of panel saw suppliers interviewed by WOOD & WOOD PRODUCTS for this article, research and development activities have centered on the ability to minimize setup and reduce downtime by integrating panel saws into the entire manufacturing operation and making them easier to program and operate.

"With current software and control technologies, a customer need only enter dat manually one time -- at the order entry point -- and all information handling through the cutting of the panels is subsequently done electronically," said Bill Pitt, vice president/general manager of Holzma U.S., div. of Stiles Machinery Inc. "The bill of materials is generated and flows automatically into the optimization software which, in turn, figures out how to cut the panels for least cost and subsequently downloads the optimized solution directly into the saw control.

"At the saw, as parts are cut, identification labels containing further machining instructions, edgebanding instructions, job name, etc. -- in alphanumeric or bar code format -- are generated on a real time basis so the correct information is linked with the correct part, simplifying downstream par tracking and machining operations," Pitt said.

Rick Hannigan, national sales manager for Holz-Her U.S., said, "We see the saw becoming part of a highly efficient and flexible work cell. In the future this workcell will require fewer people. Computers will be the brains of these cells which will also include point-to-point boring and edgebanders."

Randy Jamison, Biesse America's national sales manager for Selco panel saws, said he sees a significant increase in the "quality and intelligence of the buyers of panel saws. Expectations and knowledge have risen and with this a greater appreciation for quality engineering," Jamison said, adding, "Recent developments are really re-thinking and re-engineering of old features to bring them up to today's standards and expectations. Devices such as vertical scoring units for stacks of pre-edged efficient sequencing of patterns with head cuts and thin material loading devices. All of these special features have existed for some time but with inherent problems or disadvantages. Updating these features in regards to the engineering and efficiency of operation are all recent developments in our industry."

"The development of high level software for office use and control of the machine has eliminated the requirement for machine floor programming," said Joh Park, general manager of SGA. "In addition, active graphics, bar code generatio and production statistics available at the machine allow for better shop floor control, including the ability to better precalculate inventories."

Added George Force, president of Force Machinery Inc., "The goal is to have a paperless interface between the office and the machine operator. The ability to program saw instructions in the office -- in a cleaner, quieter environment -- and then download programmed information directly to the saw is a real plus. I can only think of one panel saw customer I have talked to in the last three years who was not interested in having the ability to download. Downloading software is now taken as a given by panel saw purchasers. It is no longer an option."

The PC conversion

"Until recently the factory floor lagged behind the front office a little bit," said John Linss, vice president -- sales and marketing for Giben America Inc. "Now wood-working companies are making more effort to bring the factory into th overall production equation by integrating all programming functions in the front office and linking several personal computers together to control the entire production process.

"I think the most significant development to making this integration possible i the switch to computer standard technology," Linss continued. "Typically this means that IBM-compatible PCs, in conjunction with mainframe or network servers are being used to control the flow of information and production in the factory This trend is directly related to the fact that IBM-compatible computers are no being effectively used as machine controllers.

"In addition, due to the fact that a basic PC is being used as a control system the proprietary nature of the controller is eliminated. Therefore, in the event of an emergency, the machine can be operated by an ordinary office computer. An finally, the internal components of the computer, while industrial grade, are interchangeable with those available from any local computer store," Linss said

Larry Tolbert, technical support manager for Richard T. Byrnes Co. Inc., was on of several panel saw experts to concur with Linss on the significance of the conversion to IBM-compatible controllers. "Up until a few years ago, most of th computer controllers used by panel saws were proprietary," Tolbert said. "Now, with a few exceptions, panel saw manufacturers are using IBM-compatible compute controllers just like the ones being used in the front office. Because just about everyone uses a personal computer in their business, the move to IBM-compatible panel saw controllers makes it easier for end users to zip up th learning curve. Plus, the increased familiarity with the systems greatly helps reduce the margin for error."

Jeff Farr, brand manager for Gabbiani Macchine, div. of Tekna Machinery, was th only person interviewed to question whether IBM-compatible controls are necessarily an improvement. He said that controls, such as those manufactured b Siemens, are better suited for industrial applications, including the comparatively harsh environment of the woodworking shop floor.

User friendliness

Regardless of what brand of computer controller is used, Farr and others noted that they are becoming more user friendly for programmers and operators alike.

"The controllers are becoming more user friendly through the use of menu-driven controls," Farr said. "As with all technology, the ultimate goal is to make the panel saw operation fool-proof. The use of Window menus helps lead the operator from one step to another. A major benefit is that much less time is required fo training. This is a significant plus when you consider how high of a turnover rate there is in this industry."

Added Linss, "Today's computers offer the option of advanced graphic displays. These graphics are more than nice pictures. They are actual simulations of the operating machine -- in real time -- with full operator control over machine functions. This gives an operator the advantage of seeing exactly how a pattern must be processed, thus taking the guesswork out of the cutting operation because the software leads the operator through the cutting. This is especially beneficial for complex cuts."

"For complicated cuts where a third or fourth cut is required, the use of enhanced color graphics is getting more popular," Tolbert added. "The graphics can help an operator get a higher yield from the cut."

"The fact that the displays are in color makes it easier for the operator to perceive and understand the information being shown," Pitt said. "Pattern setup is done with a CAD process rather than machine instructions, so the operator is basically drawing a picture of the cutting pattern rather than entering complicated program steps. Also, most controls are menu-based with clear 'prompts' and 'help' screens to lead the operator through the cutting process."

Andy Johnson, vice president of sales and marketing for Schelling America, said one of the keys to simplifying the optimizing process in panel sizing operation rests in the development of user-friendly support software technology. "As optimization software become ever more complex, it is important that the progra which is used obtains the maximum yield with the minimum complexity of cutting patterns or stacking programs. For most medium and large size producers, even a small percentage difference in the area of optimization can make a significant dollar value difference in operating costs."

Johnson added, "The refinement in recent years of color moving graphics clearly shows the saw operator information on the parts coming off the front of the saw and the turning sequence required for subsequent cuts. There have also been big gains in recent years on the troubleshooting aspects with clear text error messages and clear text solutions being automatically displayed on the screen i the event the machine develops a fault. Also, the ability to link the machine via a telephone modern directly to the service facility along with the graphic displays of various parts of the machine, help to physically identify trouble spots."

Noting that the term "user friendly' is a buzz word that tends to be overused, Jamison said, "Graphic-oriented controls are a useful tool, but they do not automatically mean that the control is user friendly. Animated or real time graphics are being used to express the level of user friendliness. Although the argument that a picture is worth a thousand words is used to promote the usefulness of the graphics control, the actual programming and process that produces these graphics are never really described until the machine is purchased and proper training is provided. Not until this training process begins can the level of user friendliness be determined."

Faster panel saws

Panel saws are not only becoming more computerized, they are being built to cycle quicker.

"The most significant development in technology has to be speed," said Farr. "Over the past two years the speeds of panel saws have almost doubled. As a result, high-production facilities can realize increased productivity with a much lower capital investment."

George Force, president of Force Machinery Inc., said, "Today's panel saws are very fast and have reached a limit in cutting and speed feeds. To make panel saws more productive, idle time spent punching buttons and programming has to b reduced, and it has." To accomplish this goal, Force said, "The electronic positioning systems for rip and cross cut fences are incredible. Everyone has cranked up the speeds of the saw carriage and the speed of the saw carriage return. Plus, the feed speeds of panels saws have been increased."

The speed increases have been facilitated by the use of brushless AC servo motors. "AC servo brushless motors can reach top speeds quicker and stop quicke and more precisely than DC motors," Farr said. "lt's not so much the carriage speed, but the pusher feed that will dictate the speed of the panel saw," Farr added. "It is more important for the pusher to cycle at a faster speed than the saw carriage because it is the pusher speed that will ultimately dictate how fast a panel can be cut.

Another advantage of AC brushless motors cited by many of the panel saw experts interviewed for this article is that they require less maintenance because they have fewer components.

"From a practical standpoint, travel speeds will only have so much impact on th time it takes to dice up a panel," Force said. "There is a definite speed limit to the saw blade's ability to achieve a high quality cut and long life of the blade."

On another level, Force and other panel saw suppliers noted that they are selling more machines with lift devices to reduce manual material handling and related downtime.

In addition to the changeover to AC brushless servo motors, Rusty Denson, sales and product manager for SCMI, said improvements have taken place in the guide systems, such as the use of double rack-and-pinion pusher fences and improvements in material clamping devices. "The rack and pinion allows the saw to hold greater tolerance at greater speeds. The clamps prevent the materials from sliding when stacking sheets. Without the clamps, the greater operating speeds would cause the piece to lose contact with the position fence, which would hurt the cut."

Park added. "Machines for panel sizing can be divided into two groups. The firs group of machines are the traditional single beam or angular cutting systems designed to cut a large panel into smaller element components. The second group is comprised of machines for high-speed strip lines which cut the panel into strips, parallel size on a combination machine and then cross cut the strips into the elemental components.

"The correct application of this technology involves an understanding of the accuracy desired, the production capacity and the downstream edge treatment tha is required. The most significant recent development involves the correct application of high-speed rip and cross-cut systems, combining the technology o the angular saw line and the high productivity of the manufacturing line resulting in decreased labor costs, less material handling and higher productio capacity. For the highest production shops, this means applying a multi-rip saw to cut strips for the highest possible output."

Digital stops

While the makers of beam saws put their stock in computers, manufacturers of vertical panel saws and sliding table saws are integrating digital readouts and stops in their equipment to speed up the process.

According to Bob Jardinico, Streibig product manager for Colonial Saw, "The availability of automatic digital stops for vertical panel saws is a significan new development. As the cabinetmaking environment shifts more toward a just-in-time basis, and as the market forces production cabinet manufacturers t offer even more choices, the demand for a high-production "off-line" saw continues to increase. An automatic vertical panel saw, coupled with an automatic digital stop system, basically eliminates much of the set-up time, while also offering increases in accuracy and repeatability."

Hannigan added, "We are selling a lot of digital readouts on our saws to the point that it is becoming more of a standard. The digital readout can convert metric to inches and visa versa. It's a tool that can help shops become faster and more efficient."

Available panel saws

Giben North America offers a wide range of panel saw technology. Giben recently introduced the Model 17/G-Drive angular panel sizing system. It features the G-Drive machine control, which combines a standard off-the-shelf IBM PC with Giben Optisave software. Benefits include integrated diagnostics and preventive maintenance features for easier troubleshooting. By using a modular programmabl logic control, proprietary control hardware is eliminated. A standard office PC can be used for the machine in the event of controller problems.

At IWF '94, Schelling America introduced the Model FM, a 3-inch book panel saw. The FM is a second generation machine of Schelling's FI series panel saw and features a number of mechanical and electronic improvements. The machine features heavy-duty construction and is capable of high-speed, accurate operation.

Holzma-U.S., Div. of Stiles Machinery Inc. has introduced its new HPL22 saw available in front loading, automatic rear loading and angular system configurations. Features include: 5.4-in. blade exposure, up to a 40-hp main sa motor, fence positioning speeds of up to 230 fpm, saw carriage return speed of 330 fpm, all-electronic measuring system for the fence and rack-and-pinion driv of the saw carriage.

European Woodworking Machinery offers AnThon panel saws featuring heavy-duty construction. By integrating a turn table in front of the rip cut saw, the saws can perform one or multiple head-cuts. Even alternating cuts, for example ripcut, headcut then ripcut, are possible without any manual material handling in between. The programs of the AnThon saw control present themselves on the screen as windows and menus which overlay each other. The computer system is an IBM PC compatible with UNIX-based program for multi-tasking or controlling many functions simultaneously by one operator.

The Alfa 32D from SCMI is designed for the mid-size shop. The saw utilizes the Master X Plus computer, capable of downloading the leading optimizing programs in the market. Standard features include a side alignment device with two rollers for holding panels against the squaring fence, secondary clamping for the last cut, a hydraulic speed variator for the saw carriage, and fast fence and saw carriage speeds. Standard air flotation tables and nine clamps on the pusher fence ease panel movement.

The Gabbiani GDG Delta 110 is a single beam, heavy-duty panel saw offered with automatic rear loading as well as front loading versions from SGA. The machine features rack-and-pinion drive for the carriage with "Star" linear motion squar rails, a DC motor for pusher and carriage, floating double-action gripper clamps, quick-change blades and PC interface for easy programming.

Byrnes/Scheer's PA5000 series of automatic panel saws feature a durable saw frame consisting of a cast iron saw carriage guided by precision linear bearing capable of 4-in. stack cutting. All saw carriage functions are computer controlled. Scoring adjustments are all made from outside the machine while it is running. Return speed is 70m/minute. The saws can be front loaded, equipped with optional rear loading or supplied as angular plants.

Holz-Her U.S. offers the Model CA-80 beam saw, featuring an 80mm cutting capacity. Other features include: precision hardened ground steel guideways, integrated scoring unit, high-speed DC program fence with clamps, high-speed sa carriage, downloadable controller and one-man operation.

The Mayer PS 9Z high-speed panel saw from Force Machinery is a simplified CNC machine that provides user-friendly programming and determines cutting lengths and cutting heights automatically. It also senses thicknesses and lengths to allow for automatic cutting and reduced set-up times.

Gabbiani Macchine's "Plus" angular cutting System is a compact machine constructed with a sturdy frame available from Tekna Machinery. It has brushles motors and a patented quick-change blade system, as well as heavy-duty brass wheels. It is equipped with a sophisticated multiaxis control capable of workin in diverse climates, the company says.

The Selco WN 200 from Biesse America features a post forming scoring saw and automatic projection of the main saw blade, a quick-change saw blade system, pneumatic panel grippers and rotating station, and a full-length additional pressure beam for clamping panels on the last trim cut. The control panel features CNC "assist line" and Digiset electronic control for scoring saw alignment; a 12-in. graphic screen; and PC with optimization software.

Available vertical panel saws

The Positron automatic digital stop positioning system increases productivity b virtually eliminating set-up time on Streibig vertical panel saws, according to Colonial Saw. The system allows the operator -- or shop foreman -- to input, sa and password-protect up to 255 separate measurements, which can be quickly recalled as needed by a push of a button. The measuring stop then automatically positions itself for the desired cuts with an accuracy of 0.004 in., Colonial Saw says.

Adwood Corp. offers a new vertical panel saw made by Elcon, which includes the patented "Limpio" dust extraction system. This feature reduces the percentage o dust released into the air by constantly removing dust from the front and back of the panel at the cut point. With this new system, panels are continually supported over the full height of the panel during cutting.

Hendrick's PRO-V vertical panel saw is able to repetitively cut small pieces from 1/2-in. squares to 5-ft by 10-ft sheets. Other features include: a full length pneumatic hold-down bar for chip-free cuts, single-blade scoring for lower tooling costs and cutting lengths of 102 in. to 126 in. A computerized version is available.

The GMC KGS 510 vertical panel saw from Atlantic Machinery Corp. features a 4.8-hp motor that operates at 5,800 rpm, accurate flip-down stops, a 14-ft maximum length of cut, a 77-in. maximum height of cut and a 10-in. carbide-tipped saw blade. The company also offers a larger model with many available options.

The Model SR-5 is a full-time panel saw and a part-time panel router available from Safety Speed Cut Mfg. Co. Inc. The machine comes with a 2.5-hp Milwaukee saw motor and 2.25-hp Milwaukee router motor, a mid-way fence system and a flow through frame style. The Model SR-5 also includes a vertical lifting router handle and a floating mounting plate.

Available table saws

The F-45 POSIT machine from Altendorf America, Div. of Stiles Machinery Inc. features a CNC controlled rip fence that enables the operator to enter up to 30 standard cutting dimensions and recalls them at the touch of a finger. When activated, the fence automatically moves to the required position.

Eric Riebling Co. Inc. offers the re-designed T-72A sliding table saw manufactured by Otto Martin Maschinenbau. It incorporates a digital read-out display on the rip fence which can be adjusted from both left and right positions of the sliding carriage by handwheel. Other new options include digital LED read-out for the cross fence, an overhead saw guard and push button control of main scoring saw with speed indicators.

Delta International offers the RE-35 table saw featuring a 7.5-hp main motor an a 0.75-hp scoring motor. It handles conventional operations such as ripping, crosscutting and mitering, plus beveling and dadoing.

Wadkin USA's CP32 siding table saw has a 9-hp main motor and features a scoring saw and 10-ft by 4-ft working capacity.