Logbuild--CAD/CAM system for log houses/Rastiniu namu cad/cam projektavimo sistema logbuild.
Portjanski, L. ; Nekrassov, G. ; Zahharov, R. 等
1. Introduction
The popularity of the houses constructed from natural materials is
increased lately. The wooden logs with round section are the good
example of such materials. Today the log houses are designed and
manufactured globally. The manufacturing environment during later
several decades has changed very much; it became modern and competitive
for mastering new design and manufacturing methods in many industrial
fields. The need of new products development and processes manufacturing
engineering at the same time has increased. The increase of new products
variety and performance, and decrease in production volume, product lead
time and manufacturing cost pursues the developers and researchers to
search new efficient methods and techniques for manufacturing
engineering [1]. Navackas has developed the 3-D model for lateral
etching processes, which is possible to apply in new device
manufacturing processes [2]. At the same time Burneika has developed the
product configurator which enables a user to make product adjustments
[3]. Karaulova [4] researched manufacturing process reliability.
The problem is that the specific peculiarities of log houses (Fig.
1) are not fully covered by the existing architectural CAD systems, and
as a consequence the design is carried out manually. The existing
architectural CAD systems give the graphic image of a design, kinds,
sections and 3D views and the main integrated characteristics of a
building (volume building materials, area of elements and etc.) [5, 6].
In such CAD systems it is difficult to create the complete Bill of
Materials (BOM) and it is not possible to describe the parts
manufacturing process during the log house design. The integrated
CAD/CAM system for log houses was designed in order to eliminate those
drawbacks. The list of problems that should be solved by the integrated
CAD/CAM system is:
1. The design and creation of technical drawings of log houses are
simplified. It is a traditional problem of architectural CAD systems.
The CAD system for the wooden design should meet additional
requirements:
* taking into account the overhang of logs for the design
durability;
* the walls height should consider the ratio of logs;
* the positions for windows, doors and apertures and their mutual
coordination at crossing of walls should consider the frequency rate of
the logs;
* an automated positioning of rafters and planks.
2. House specification or Bill of Materials (BOM) should include
not only the list of components (like windows, doors), required for
house manufacturing, but also the separate logs of required length with
the indication of location.
3. The House routing includes the list of manufacturing process
operations for each separate log. This routing can be created
automatically after the analysis of the main constructive elements of
the house and additional elements is performed, when the characteristics
of each log are given. The related problem solved--is the computation of
dimensional chains in order to define the location of each processed
element.
4. The manufacturing process optimization for all logs, included in
the design of a log house. The optimization enables to minimize the
material waste through leftovers reuse and to maximize the use of
surplus, left from other houses.
[FIGURE 1 OMITTED]
2. Log house design
The design of a house consists of the following basic elements [7,
8].
* The main axes of the house are building axes. For log houses
design the main axes are placed in parallel to mutually perpendicular
axes X and Y of the plan. Usually these axes are marked by letters in
one direction and by figures in perpendicular direction. The main axes
are the basic dimensional characteristics of the house, the reference
point. The other elements are bind to this point which simplifies the
size changes and movement of the elements. If the size of the main axes
is changed, all the other elements connected to these axes will be
automatically resized. The knots of the building are formed in the
points of main axes cross-section (Fig. 2).
* House wall. The walls can be located only on the main axes (Fig.
3). The extent of a wall is also given from the main axes. However the
extend of the wall, dependent on the overhang of logs, should be
considered for the durability of the house design.
* Windows and doors. For those elements a user is able to prepare a
catalogue of typical sizes. While placing a given element the special
attention is given to the definition of the vertical sizes of the hole
under this element. The real hole should be increased by the size of the
house shrinkage (= 6%). Appropriate real bogus hole is placed in such
way that its bottom is located on the border of the complete log (in
view of the direction of an axis). Thus bogus hole, used for
installation of logs, can be less than real. It means that later a
hollow will be made on the appropriate log. The system also aligns the
top of the holes, so that they are of the same height.
* Apertures are used to indicate that there are some logs missing
in particular place of a wall. The created aperture is mirrored at the
crossing wall, providing the correct joint of perpendicular walls.
* Roof. The system can build practically any kind of roofs starting
from simple flat, shed, gable up to complex ones. The walls are
automatically trimmed or extended to fit the roof. There is the
possibility to move axes under the roof in a manner, that the height of
a wall satisfies condition in Fig. 4. The circuit of the arrangement of
rafters is formed automatically accordingly to the height difference of
mutually perpendicular walls.
* Floor and ceiling. The system supports computation of various
types of floors and ceilings: simple, with additional insulation, with
black floor and their combinations. Automatic arrangement of planks is
carried out, and the calculation of all necessary parts of a floor
or/and ceiling is made. Floor and ceiling planks quantity and lengths
(l) calculation scheme are developed, based on room dimensions and
curvature of the wall surface.
* Auxiliary elements. Such elements are axes under probes fastening
a design, holes for wiring, peculiarities of the logs and etc.
* Logs.
[FIGURE 2 OMITTED]
The durability analysis showed that the log overhangs (B) depend on
its diameter (D). The following empirical equation for the overhang
value calculation, that ensures good industrial results, is introduced
as
B = 1.17D (1)
The calculation of the wall height is the topic of special interest
for log houses. In order to keep the correct connection between logs,
walls of one direction begin with half logs, while perpendicular to them
with whole logs. The height of the wall depends on the wall direction
and the size of the rise of the wall after stacking of one log. The
scheme of stacking of logs is given in Fig. 4. By this scheme it is
possible to calculate the empirical dependence of the height of the rise
on the diameter and the height of a wall [H.sub.w] based on collected
experimental data, where N is a number of lines in wall.
H = 0.88D (2)
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] (3)
l = ([T.sub.2] - [T.sub.1]) - D + [K.sub.p] (4)
where [T.sub.1] and [T.sub.2] are axial dimensions of the walls
forming a room; D is log diameter; [K.sub.p] is wall surface curvature
is calculated accordingly to plank's position against axis of a
log--plank is below log axis or above it (Fig. 5).
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] (5)
[FIGURE 3 OMITTED]
[FIGURE 4 OMITTED]
[FIGURE 5 OMITTED]
3. House specification
The list of typical sizes is made for the windows and doors. The
designation of those elements is given on the technical drawing. In
addition general length of plat bands is computed.
The list of used rafters and planks, general length of boards for
floor, ceiling and roof, and the total characteristics of additional
elements such as warming, laths for black floor and etc. is made for
roofs, floors and ceilings.
In order to create the list of logs automatically, it is necessary
to place all the logs on the walls and if required changes could be
manually done by designer. The offered allocation algorithm takes into
account the requirement to arrange the logs with the length more than 6
meters on rows in chess order. It also eliminates the possibility to
place the log in holes for windows and doors. It computes the length of
the log under inclined roof and checks joint logs on crossed axes. The
algorithm enables to start the walls from the half or whole logs. In
specification the designation is marked on the each log accordingly to
the following structure
XX - YYY/ZZ (6)
where XX is name of a wall; YYY is serial number of a line; ZZ is
serial number of the log in line.
[FIGURE 6 OMITTED]
It enables to assemble the house in the correct and simple way.
The following information is provided by the system.
1. The timber processing technology, which includes:
* logs processing technology, which considers the special features
of equipment;
* drawings and production technology of trusses, floor and ceiling
planks.
2. The full specification of the house, which includes (Fig. 6):
a. House overall support structure:
* the total length of main logs 1, including columns 26;
* the amount of insulation installed between logs 18; the
appropriate amount of waterproof membrane installed between the wooden
part of the house and the foundation 4;
* the list of windows and doors by type and dimensions, accordingly
to company internal specification or client specific nomenclature;
* quantity and length of casings 19 and visors 22, considering
their mounting specifics;
* quantity and length of guiding planks 20 and columns 21 for
windows and doors installation;
* quantity and length of fixing wood dowel pins 34, fixing bolts
35, columns adjustment bolts and structural elements of the house, that
do not shrink 36.
b. Floors and ceiling construction:
* quantity and length of floor planks 5.1, terrace planks 5.2,
ceiling planks 5.3 and secondary floor planks 29;
* the quantity and length of floor 25 and ceiling plinths;
* the quantity and length of black support floor joists 31 and its
timber planks 32;
* the quantity and length of floor joists 7 and terrace
joists 8;
* the quantity and length of ceiling lining planks, both horizontal
11 and attic ceiling (under roof) 9;
* amount of insulation for floor 3, roof and additional insulation
for walls, considering their thickness.
c. Roof construction:
* quantity and length of rafters 2 and secondary rafters;
* quantity and length of inter rafters planks 14;
* quantity and length of roof lining planks 12;
* quantity and length of timber roof battens 13;
* quantity and length of cornice planks 16, 17;
* quantity and length of visor lining planks 10;
* quantity and length of columns 24 and walls internal lining 6.
d. The additional house elements:
* quantity and length of walls internal lining or main plank
imitation 6;
* quantity of metal fittings (frame and rafters fixture sliding
elements 23, connection strip 37.
e. Main logs packing scheme given either to assembly order or the
maximum packing density.
4. Technology formation
If to consider a separate log placed on a wall it is possible to
notice, that the main constructive elements of a house, concerning or
crossing this log, form geometrical entities (GE) on it. These
geometrical entities are given in Fig. 7.
* Log end faces--are defined by the borders of location of the log.
* Cut at the end face takes place if the log contacts the left or
right border of aperture under window.
* Cut on length--arises at the crossing with the real
aperture under door or window.
* Cut for joint logs--arises at the contact or crossing with the
wall.
* Aperture under a fastening--arises at the crossing with an axis
under fastening probes or with a wall.
[FIGURE 7 OMITTED]
Their main characteristic, except their sizes, is the distance from
the left-end face of log to base axis or geometrical entity (GE). Each
GE is an elementary cut surface. It means that one operation of a
technological process is required for its processing. If to arrange the
geometrical elements incrementally the sequence of processing of the
given log is received as a first approximation. The developed heuristic
algorithm engages GE in the sequence required for processing in case of
identical distances (Fig. 8).
[FIGURE 8 OMITTED]
To calculate those dimensions the sizes of the main axes of a house
(on plan) are bind to the axes of coordinates OXY (Fig. 9). An adjacency
matrix of graph G on the axis X is made. The given problem is
characterized by the fact that the meanings of elements of the adjacency
matrix can be negative if the direction from one top to another is
opposite to the direction of axes of the chosen coordinate system.
We shall designate as [a.sup.i.sub.j] the number of arches U, going
from [x.sub.t] to [x.sub.j]. The square matrix A = ([a.sup.i.sub.j])
with n rows and n column refers to the adjacency matrix the graph [9,
10]
G = (X,U) (7)
where [x.sub.1], [x.sub.2],..., [x.sub.n] are top of the graph G;
[a.sup.i.sub.j] is element, worth on crossing of row i and column j;
[a.sub.i] = ([a.sup.i.sub.1], [a.sup.i.sub.2],..., [a.sup.i.sub.n]) is
designates i--a vector a row; [a.sub.j] = {[a.sup.1.sub.j],
[a.sup.2.sub.j],..., [a.sup.n.sub.j]) is designates j--a vector a
column.
[FIGURE 9 OMITTED]
We shall define two operations, which we shall name as generalized
addition [[lambda].sub.1] [direct sum] = min ([[lambda].sub.1],
[[lambda].sub.2]) and generalized multiplication [[lambda].sub.1] [cross
product] [[lambda].sub.2] = [[lambda].sub.1] + [[lambda].sub.2].
We shall consider two matrixes A = ([a.sup.i.sub.j]) and , B =
([b.sup.i.sub.j]) elements of which are real elements, then the
generalized sum of these matrixes is a matrix
S = A [direct sum] B = ([s.sup.i.sub.j]) (8)
where [s.sup.i.sub.j] = [a.sup.i.sub.j] [direct sum]
[b.sup.i.sub.j].
The generalized product is a
P = A [cross product] B = ([p.sup.i.sub.j]) (9)
where [p.sup.i.sub.j] = ([a.sup.i.sub.j] [cross product]
[b.sup.1.sub.j]) [direct sum]([a.sup.i.sub.2] [cross product]
[b.sup.2.sub.j])[direct sum] ... [direct sum]([a.sup.i.sub.n] [cross
product] [b.sup.n.sub.j]).
For graph G, each arch a which has referred length l(u), we shall
consider a matrix A
A = ([a.sup.i.sub.j]) (10)
where [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII]
For example in Fig.9 we receive the following matrix of the sizes
of the main axes of the house on coordinate axis OX, taking into account
their orientation:
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] (11)
The common element of the matrix A is equal to [a.sup.i.sub.j] =
min ([a.sup.k.sub.i] + [a.sup.j.sub.k]), where [a.sup.i.sub.j] is the
dimension between walls [p.sub.i] and [p.sub.j].
As it was previously mentioned we are able to find all missing
dimensions, by using described algorithm of generalized product of
matrixes
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] (12)
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] (13)
There is a certain natural number N, for which the condition
[A.sup.N] = [A.sup.N+1] = [A.sup.N+2] = ... is carried out. For our
variant [A.sup.3] = [A.sup.4] = [A.sup.5] = [A.sup.N].
The given matrix and algorithm of generalized multiplication are
used in the offered system for finding all the dimensions between
geometrical elements of the house on all coordinate axes.
5. Optimization of manufacturing
In the following chapter, we shall use "trunks" for work
pieces to produce some logs. This problem is one of the particular cases
of optimal material consumption. It can be formulated in the following
way. Suppose we have trunks with k different dimensions. We want to cut
these trunks into m different logs (Fig. 10).
[FIGURE 10 OMITTED]
A trunk with given size s (s = 1, 2,..., k) could be split by
[n.sub.s] in different ways. Using j method we could produce
[a.sup.(s).sub.ij] logs of the size i from trunk s (where j = 1, 2,...,
[n.sub.s]; i = 1, 2,..., m). The cost of one trunk is proportional to
its length [C.sup.(s)] ~ [L.sup.(s)]. Hereinafter we consider the length
in objective function. [C.sup.(s).sub.j] is the cost of waste after
cutting the trunk s by the method j.
The total quantity [N.sub.i] of each type of logs is given, which
should be cut up from all trunks and the quantity [M.sub.s]. of each
size we have.
It is required to discover, how many trunks of each size we need,
get [N.sub.i] (i = 1, 2,..., m) trunks produced from these by each of
possible methods [x.sup.(s).sub.j], taking into account that the total
length of all used trunks should be minimized in order to avoid the
waste.
Hence, this problem will be formulated in the following way. It is
required to find a minimum of objective function [11]
L = [k.summation over (s=1)][[[n.sub.s].summation over (j=1)]
([L.sup.(s)] - [L.sup.(s).sub.j])[x.sup.(s).sub.f] (14)
in condition: [k.summation over (s=1)][[n.sub.s].summation over
(j=1)][a.sup.(s).sub.ij][x.sup.(s).sub.j] [greater than or equal to]
[N.sub.i](i = 1,2,..., m),
[[n.sub.s].summation over (j=1)][x.sup.(s).sub.j] [less than or
equal to] [M.sub.s](s = 1, 2,..., k),
[x.sup.(s).sub.j] [greater than or equal to] 0 (s = 1, 2,..., k; j
= 1, 2,..., [n.sub.s]), [x.sup.(s).sub.j] -int eger.
The equation shows, that we have to produce given quantity of logs
of type i using all trunks of the sizes k and all the methods. There
will be as many equations m of such kind as the sizes of logs we have.
Inequalities show that we have to cut only the given quantity of trunk
with the given size s.
The objective function can be transformed, if some assumptions are
made. It is possible to minimize the total length of waste, or the
length of all trunks, i.e. to minimize the objective function
L = [k.summation over (s=1)] [[n.sub.s].summation over (j=1)]
[F.sup.(s)][x.sup.(s).sub.j] or [L.sub.j] = [k.summation over (s=1)]
[[n.sub.s].summation over (j=1)] [F.sup.(s).sub.j][x.sup.(s).sub.j] (15)
In this case the problem is formulated as follows: from trunks of
one given length (s = 1) it is necessary to produce logs with m
different lengths. One trunk can be split on length by n in different
ways. In case when we use j method from one trunk we will get [a.sub.ij]
logs of type i (i = 1, 2, 3, ..., m; j = 1, 2, 3,..., n) and
[c.sub.j]-size of waste from the trunk. We have to produce [N.sub.i]
logs of type i.
It is required to find the total number of trunks [x.sub.i], which
we split by the j methods in order to produce the given quantity
[N.sub.i] of logs of each length with minimum waste, i.e. to minimize
the objective function
L = [n.summation over (j=1)][c.sub.j][x.sub.j] (16)
at such restrictions: [n.summation over (j=1)] [a.sub.ij][x.sub.j]
[greater than or equal to] [N.sub.i] (i = 1, 2, 3, ..., m), [x.sub.j]
[greater than or equal to] 0 (j = 1, 2, 3,..., n), [x.sub.j] - int eger.
To solve the given problem we use the method of sequential
improvement of the plan using an inverse matrix (modified simplex method
using the usual form of an inverse matrix) [12]. The solution could be
found faster if we apply the method of sequential improvement of the
plan, which uses the inverse matrix.
If when the total length of logs for building a one-storey log
house (area about 25 square meters) with a gable roof (angle
45[degrees]), is about 1200 meters, then the economy of 6-10 percents of
logs equals to 72-120 meters. It is considerable amount. Accordingly to
the case study data received from the company, where the hand-operated
design was used, the percentage of irrevocable wastes to manufacture
such a house makes on the average 13-15%. The hand-operated designing is
rather labour-consuming and requires 10-12 hours for the above described
house.
If the described algorithm is applied it is possible to reduce the
percentage of irrevocable wastes up to 2-3%. Small percentage of
irrevocable wastes is one of the advantages of the given method, but
there are several prerequisites.
* All the sizes of the trunks should be known before the
optimization method is applied. It is an advantage, because if we know
all the lengths of trunks we can quickly order the necessary logs from
supplier firms.
* The disadvantage is that the large space in the warehouse is
needed to store the elements of a house. It is possible to pre assemble
the walls on the control table only after all the logs of the house are
manufactured. Thus the size of the ready production warehouse should be
the same as the size of all the walls of the log house that affects the
cost of the house.
* It is impossible to control the optimization process before it is
completed. It can be an advantage as well as a disadvantage. There is
common situation when some part with defects is non-suitable for
production. In such situation it is required to put the given trunk a
side, in order not to change initial parameters (initial trunk length)
of the process of optimization, or to interrupt this process and to
start up it again. In such case the parts produced before excluded from
the optimization.
There are a number of restrictions in the application of the
optimization in manufacturing.
* The lengths of all the trunks are unknown in advance, because
they are coming directly from warehouse or supplied by vendors. But in
both cases the exact length of trunks, suitable for manufacturing logs
is known only after lathe operation, followed by control and
measurement.
* Some part can be damaged during the processing and should be
rejected. Such a part should be produced again. The rejected part should
be reused in production if possible. The length of the trunks should be
updated every time after lathe operation. It means that the real time
control of the optimization process is required.
* Technological process restrictions. There Work in Process (WIP)
is limited to the certain amount of walls because the warehouse space is
limited. Only after a particular wall is checked on the control table it
can be packed and transported.
* In splitting process the longest logs should be produced first.
For this purpose the processing is started from the walls with the
maximum average length of the logs.
In the conditions of the real factory it is not possible to
consider all and authors offer to solve the problem of optimization by
step-by-step method. This method consists of searching a local minimum
waste of each trunk being manufactured. Although involvement of a person
in the process of optimization does not permit to receive a global
minimum, it provides decision close to it.
The process of local optimization consists on the following
operations. At the beginning a longest part of the first wall in
production is made from the trunk of the given size. The surplus left is
used as another trunk for recurrence of the previous step of search. The
priority of possible splitting method function selection depends on the
size of surplus and the quantity of logs made from trunk in use. Later
the process is repeated for a detail of the main wall.
As the result the optimization function offers to the user several
variants with the least priority. The user operates with the offered
variants of splitting and the function of priority based on the quantity
of logs, that is possible to receive. The user can change the initial
parameters in order to reduce the quantity of variants. The acceptable
choice can be done if the size of the surplus and the quantity of logs
are known (Fig. 11).
If there are no suitable additional logs in the main wall, the
system is able to select the additional logs from any other wall. Any
available wall can be manually added by the user or the most suitable
one can be selected automatically.
If the user is not satisfied with result of the optimization, the
system enables to repeat the process of optimization from any point. The
surplus from the manufacturing process and defect log are stored in the
warehouse and can be used for logs if required and the waste information
is available to the user.
The developed service tools enable to search for the information
related to additional and available walls. This information is used for
the process of local optimization (review of amount and lengths of logs
making a wall). Those tools also show the total percentage of waste and
amount of produced logs and walls.
The optimization enables to order the amount of logs required for a
particular house manufacturing. In addition this model also supports the
preliminary optimization, when the parts are not directly manufactured,
but used as the base for the formation of the logs list. This data is
used later for the complete optimization.
It is possible to output the result of optimization with the
technology of processing of each detail directly to the screen, to print
it out or to forward directly into NC machine.
The optimization algorithm described above is also used for the
parts packing list creation, with minor changes of input and output data
parameters. The optimization parameters are also different. For example
the width of the cut is equal to zero and acceptable waste percentage
(empty space in a series of one package) can be up to 15%. The main menu
of optimization is presented in Fig. 11.
6. Conclusion
The optimization algorithm and the integrated CAD/CAM system for
log house design and production was developed by authors. The software
system is written on algorithmic programming language C++ and is
implemented in production at the "PALMATIN" company. The
software is used both for the automatic design of timber and log houses
and for processing technology of all logs with minimum material waste in
manufacturing process.
The following tasks are solved by developed CAD/CAM system for log
houses:
* wooden house structure design and creation of technical drawings;
* specification of house complete parts list;
* generation of processing technology for each individual log;
* calculation of dimension chains;
* Optimization of production and packaging of logs. Accordingly to
the data received from "PALMATIN" [13] company the waste
percentage was reduced by 10-12%, compared to manual optimization. The
time required for house design and optimization was reduced 80 times.
The results of the offered optimization methods analysis are given in
Table.
Acknowledgements
Would like to thank the Estonian Science Foundation for the
targeted financing schemes SF0140113Bs08 and SF0142684s05 that enabled
us to carry out this work.
Received June 16, 2010
Accepted December 07, 2010
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L. Portjanski, Tallinn University of Technology, Ehitajatee tee
5,198086 Tallinn, Estonia, E-mail: leonid.portjanski@ttu.ee
G. Nekrassov, Tallinn University of Technology, Ehitajate tee
5,198086 Tallinn, Estonia, E-mail: grigori.nekrassov@ttu.ee
R. Zahharov, Pharmadule OU, Kesk tee 22, Juri, Rae vald, 75301
Harjumaa, Estonia, E-mail: roman.zahharov@gmail.com
E. Shevtshenko, Tallinn University of Technology, Ehitajatee tee
5,198086 Tallinn, Estonia, E-mail: eduard.shevtshenko@ttu.ee
Table
Comparison of splitting methods
Full Local
Name Manually optimization optimization
Design time (hour) 10-12 0.5-1 1-2
Percentage of 13-15 2.5-3 4-5
material waste
Design control Full Lack Full
Fig. 11 Main menu of optimization opportunities
Loghouse name: example Trunk length: 600 Total waste
Working walls: 8 Waste length: 0.0 %
Amount of logs in Number of logs from 2.7
wall: 11/30 trunk: 2
Reiteration
Variants of splitting parameters Serves
Waste Change waste length View working wall
20=520>8-15/2+60>8-18/1
Waste 50=550>8-16/2 Change number of View all walls
logs from trunk
Waste Automatically add Delete additional
60=480>8-15/1+60>8-18/1 new additional wall wall
Waste Manually add new Printing
210=195>8-13/4+195>8-12/4 additional wall
Waste Change additional Reiteration
315=150>8-10/2+135>8-14/3 wall
Waste Correct mistakes
330=135>8-14/3+135>8-13/3 or rejection
Waste 540=60>8-18/1 Make from waste
Change initial
parameters