The Forestry Forum

General Forestry => Firewood and Wood Heating => Topic started by: Higgo on June 19, 2014, 11:07:21 PM

Title: Processor Build, Home Made Firewood Processor
Post by: Higgo on June 19, 2014, 11:07:21 PM
Hi everyone, I've been looking at everyone else's processor builds for a couple of years now so I thought I had better share some pics of mine! It's not finished yet... I've been working on it very slowly for around 2 years but haven't really had the time until recently to actually make some headway! Anyway I'm using a 30g Danzco saw and the rest is built around an E2700 Mazda diesel truck chassis. I think it was originally around a 4 ton truck. I ripped the cab off and the tray. I've left the motor and running gear as it was. The motor is an XA 2.5l diesel. I'm told a licensed copy of a 4 cyl. Perkins. It makes 75hp. I'm currently working out the hydraulic side of things.  I did my apprenticeship in a hydraulics shop but never had to build a system (only machine components!) so I'm new to system design... and I don't like doing things twice! Any recommendations to my machine design are welcome. I'll try and get around to taking some better pics. The saw at the front of the machine is in the basics position. I mocked it up using the drum so I could see how it sits. Should I make My machine drive-able using the original running gear? or make my own hydro-static drive wheel? Or trailer it and drag it with my excavator or truck? It will be cutting long plantations of sugargum and will need to regularly move along. I'd like to have so sort of operator cab to protect from the elements. Any suggestions are welcome.
Had to redo the photos I think I did it wrong the first time!

(https://forestryforum.com/gallery/albums/userpics/36796/20131014_184438.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/20131223_185332.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/20131223_185350.jpg)

Title: Re: Processor Build
Post by: beenthere on June 20, 2014, 12:01:15 AM
Welcome to the Forestry Forum.

Nice job on the pics, and right out of the box too. smiley_thumbsup

That is a healthy cutoff saw standing poised and ready to knock off a block.

Thanks for jumping in and contributing to the processor builds.

Your general location in your profile bio will be a nice addition. Also a thread about making firewood out of sugargum would be great too.
Title: Re: Processor Build
Post by: Higgo on June 20, 2014, 02:02:26 AM
I've got a symbolic diagram for the hydraulics but haven't joined the dots yet... if anyone has any recommendations or wants to join the dots re: hose size/valve choice please let me know! I was hoping "someone" could draw in the type of valves/hose connections in need! When I get a chance I'll try and draft my initial diagram. Port sizes for the 3 small cylinders (i'll have to check) are 3/8" NPTF, the splitter cylinder ports are about 1" diameter hole but not sure of thread size (need to double check). I just want to make sure I've got things sorted before I get the whole thing plumbed up and from what I've read on here a lot of people have trouble with the plumbing on their machines. I've got a similar thing on another forum asking for help if it looks familiar...  splitwood_smiley

(https://forestryforum.com/gallery/albums/userpics/36796/Presentation1.jpg)

Title: Re: Processor Build
Post by: r.man on June 20, 2014, 07:53:18 AM
Welcome Higgo. I am no help with the hydraulics, at best I get by, but I have an opinion about the mobility. If the drive train can remain intact I think it would be great to have it in a plantation to help with speed and to free up the pull vehicle for something else. Good luck with the build, I know what you mean about the time thing.
Title: Re: Processor Build
Post by: Higgo on June 21, 2014, 05:05:16 AM
I was thinking that too. I don't know if anyone has seen an 'island cabin' truck before but I thought that I could make a similar style cab and move the truck controls slightly to the side. The truck was originally a cab over style so I don't think this will be too difficult. Here's a picture below from google of a similar truck to the one I'm using.

(https://forestryforum.com/gallery/albums/userpics/36796/E2700_Mazda.JPG)

I was planning to use a divorced transfer case from a 4wd drive truck to split the drive shaft to enable me to drive my pump. Ideally I would like to drive it from the front of the engine but I'm not sure about the crankshafts front nose's ability to handle 60hp of hydraulic load? being that it's a Perkins engine copy it might be ok... anyone have any experience with similar setups or advice to offer?
Title: Re: Processor Build
Post by: North River Energy on June 21, 2014, 08:06:58 AM
Might just be my screen, but I can't read the pump specs off the diagram.
Gpm?
Single pump or stacked?
What's the rod diameter on the spitter cylinder?

So far as not doing things twice, some of that comes down to design philosophy, how you plan on using the machine, and how you plan to get there.
And then making sure you're on the 'right' path, before you spend too much or get sparky with the metal.

Which machines (homebuilt or commercial) do you like, and what of those machines appeals to you?

Given that the machine needs to produce splits more so than drive itself around, I'd probably relocate the engine to best drive the pumps, and then mount a large hydraulic motor to the front of the gearbox to move the chassis.

That is, if it rarely needs to leave your property.
If you plan on going mobile, you might be better off either towing it, or using a separate power plant for the business end of things.

I've got a Bedford 2.2(?) on my machine, (possibly a Perkins licensee), and it works very well.  Probably driving 70gpm if I run it to 1800rpm.

Post more details/specs and a few more photos.
Title: Re: Processor Build
Post by: Higgo on June 22, 2014, 05:13:21 AM
I'll have to do some double checking on the splitter rod size... from memory it's 2" but it might be 2.25". The pump is a variable displacement 98cc per rev. Vickers pump. I plan on running it around 1800rpm which should give around 45gpm or 176lpm. Of course I think the efficiency will be more like 40gpm. I'm thinking that I should get a 2 stage pump purely for the splitter and let the vickers pump run the saw, conveyor and the ancillary cylinders (clamp, stop etc.). Seems to be what a lot of other people have done. I'll get some better pictures of things tomorrow. Today I spent a couple of hours drilling some holes and slots for the conveyor sprocket to clear the main 'spine' of the machine. I have to do the same for the other end of the conveyor tomorrow. Here's a couple of pics of the progress today.

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140622022707.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140622022721_28129.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140622022732_28129.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140622045217_28129.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140622045325_28129.jpg)
Title: Re: Processor Build
Post by: North River Energy on June 25, 2014, 09:36:52 PM
General thoughts:
Make sure you have enough flow to run more than one function at the same time. This might involve three pumps, or super-special valve stacks and/or flow dividers. Figure out which option makes more sense economically.

It's really nice to advance the log while the bar is retracting, at the same time the splitter is doing it's thing.

Autocycle is nice, in that it allows you to pay more attention to the sawing, and can make the operator more effective in squeaking more performance out of the machine.

Was talking at the pump shop today about a valve system that can be operated manual or electric, has more configuration flexibility than Cirque du Soleil, and has some nifty features regarding flow behaviour and serviceability. 
Not cheap, though. Built for the long run.
I think it was a Danfoss product?

Go large on the fittings and hose size, except for the small flow stuff. Try to set things up with common fittings (I like JIC) so that when/if you blow a hose, you don't need something exotic on one end or the other.


Probably no need to use a high/low pump for the splitter, as that tactic is more a means of running a splitter with less hp, and you have plenty on hand. (Or did you mean a second pump body stacked on the back of the Vickers?)
Look into a dump valve for fluid return on the piston side of the splitter ram.  You'll pick up a little cycle speed, save a bit of fuel, and reduce fluid temps.
Try not to make the one machine do everything.  Figure out what size/species/product size you will deal with the most and build to suit.
The processor is just one link in the chain.  Make sure it's configured to work well with the rest of the iron.
Also do some thinking on how the operator will interact.  You don't want to go walkabout every few minutes just because you put the controls in the wrong place.
Title: Re: Processor Build
Post by: Higgo on June 27, 2014, 08:42:14 PM
Good points on the hydraulic setup. I did mean a stacked 2 stage pump on the back of my vickers pump but I agree it might be overkill. I had a look at some Eaton Mobile valves as suggested they look like they might be suitable for what I'm trying to do. I'm studying Mechatronic engineering at the moment so I hope to be able to eventually make it fully auto via plc control and only have the operator do 'mid auto manual' movements if something goes array... but in the meantime joystick control will do. I intend for it to eventually work similar to how a cnc bandsaw or lathe etc works (however I expect that a reasonable amount of operator intervention would still be required!). I have an excavator and loader/telehandler available to load the machine so I'll try and make a log deck to load up a few long logs in between. I like the idea of the operator being in some sort of cab or frame in view of the saw splitter so I was thinking of mounting the controls in the cab. Got a KAB seat out of our loader yesterday, retrofitted an air seat in its position nothing wrong with the old one just no suspension! Didn't have a lot of time to work on the machine this week but managed to spend around a day all up making the rear chain tensioner and sprocket mount, few pics below.
The chain tensionor is from an old header/combine front same pitch, ready made and free! You can see in the pics my first attempt of the sprocket mount... made it, then welded it up; stood back and it just looked too light! I intend to put some sort of rear pull on the machine in case it gets stuck in a muddy area so i need it to be fairly strong, not to mention its going to have big sugargum logs resting on it! So I cut the mounts off and remade them out of large pieces of 12mm plate that run the full height of my frame. Thanks for the feedback everyone. Sorry if I haven't directly responded to everyone's suggestions or questions but rest assured I'm taking it all in! If I've missed anything let me know! smiley_smash
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140623043949.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140623044004.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140627014746.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140627014758.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140627014810.jpg)
Title: Re: Processor Build
Post by: Higgo on July 02, 2014, 07:42:10 AM
Couple more pics of the conveyor ends, oxy cutout at the drive end to clear the sprocket boss and hole sawn and ground with the angle grinder at the driven end. I usually prefer to drill and saw rather than oxy cut but because I couldn't get the hole saw into position for one of the cuts I had to use the gas axe. The front sprocket is adjustable height and length wise to help with tracking the chain. However it is probably overkill for a simple conveyor. I had to make do with the bearing mounting positions which is another reason i went with this configuration. I'll post some more detailed pics of it once I have the hydraulic motor mounted up. I'm probably going to have to use a 'jack shaft' to reduce the conveyor chain speed to an acceptable level. I've read 65 fpm is a good conveyor chain speed to use... Anyone know or willing to measure their in-feed conveyor motor rpm or conveyor chain speed?? Just like to know before I commit to my sprocket sizes for the hydraulic motor and driven shaft.

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140701115114.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140701115153.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140702101300.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140702101245.jpg)
Title: Re: Processor Build
Post by: North River Energy on July 03, 2014, 05:13:08 PM
A cursory glance suggests that the drive ratio on mine is around 1:2, mechanical advantage favoring the drive motor.

My chain transport cogs are much smaller than yours, however.  Motor is some sort of elderly Char-lynn/Eaton with a 1" shaft and 3/8npt ports.

So far as fpm, just aim for something that keeps up with the saw and splitter, or just slightly faster.

Have you already purchased an infeed motor?  If not, might want to do some figuring to make sure you have enough torque and rpm for the job.
When it doubt, go big on the motor and then rearrange the toothcount to get what you want. 

Otherwise, make sure the chain can't jam at either end when reversed, or when slack, and try not to 'weld yourself into a corner' so to speak.
Takes longer to make bolt-on sub-assemblies, but makes servicing easier.

If you do a cab, set it up so that the operator can clear any jams without difficulty or awkward contortions.  Had a look at a fairly expensive rig where the owner had torched a few bars out of the bash guard.
Title: Re: Processor Build
Post by: TeaW on July 04, 2014, 06:07:38 PM
Checked the speed of infeed conveyor on my home made processor today , it is 120 ft /min. Faster than it needs but it doesn't cause any problem, 65 ft/min is probably good to shoot for.
I have the 20 gpm Danzco saw and am fairly happy with it. The oiler works well but it can put a lot of oil on in a hurry, the adjustment is very sensitive .I added aluminium side plates to help keep the oil on the chain, also made the chain adjustment screw the same head size as the studs, so one wrench will do it all when you change a chain or tighten it.
Title: Re: Processor Build
Post by: r.man on July 04, 2014, 08:37:08 PM
Unless you need to throw the split wood for some reason I think that the speed should be as low as possible to minimize component wear.
Title: Re: Processor Build
Post by: Higgo on July 04, 2014, 09:48:48 PM
Thanks for the replies! 120fpm is what I thought some of the infeed conveyor speeds looked like on a few commercial videos I have have seen. Thanks heaps for checking yours TeaW! Do you have a build thread or some pics anywhere on here? I've got an old Vickers motor which I hope to use for the conveyor, however I'll have to double check the specs. I think it should work because it used to run an old grain auger about 20ft. long. I might try and do the physics calcs on the conveyor and post them up to get some opinions and maybe help some other people designing conveyors... got the saw into semi position yesterday and also the oil tank (need to get some more pictures and post them of the build) Here are a couple anyway... One of the saw and one of the conveyor motor plate I may use. Anyone have a few motor specs for their machines so I can compare size/nM/psi/gpm etc? I think my ratio may end up being 1:2.5/1:2.5 (double reduction using a jack shaft). Thanks again for the replies, it's really helpful!
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140703052417.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140703104417.jpg)
Title: Re: Processor Build
Post by: johndeerkiwi on July 10, 2014, 07:00:46 AM
Great what a man can do with some metal and a welder!
Hose size is a matter of keeping the velocity in the right range, too slow a velocity is fine but it can mean you could have perhaps done it cheaper by using the next size smaller hose, a too high a velocity equals high friction losses, more heat generation, and noise, as the oil is forced at high speed through lines that are too small.
In between these two extremes is the desired velocity.
You can get hose sizing charts where you draw a line across from your known  (pump) flow to the (stated)ideal velocity range, and it shows what size hydraulic  hose to use. You will find that pressure lines are calculated differently than return lines, on these charts.
Don't forget that on a ram that is retracting, there will be a much higher out-flow, so the return line should be assessed according to that higher flow.
That's because on the retraction stroke, the oil in-flow to the rod end will be pushing somewhere near double the amount out(depending on the ratio of rod size to cylinder size used in the ram), so you need to allow for the return hose to take this higher flow.
On a typical  ram this is usually be about a 2:1 ratio, but if you get hold of a ram with an oversize rod (often used in wood splitting rams for quicker retraction) this increased flow will be even more pronounced.
The only way to really be sure is to either use a computer flow chart on the internet, or use maths to calculate the volumes.
I recommend that if you use  "experts" to do the calculation for hose size, work it out properly yourself first as a cross check,  as I've seen instances of the experts getting it wrong when they could have simply referred to the proper chart and got it right!

In the smart ideas department....the idea of using a chain tension adjusting nut the same size as the bar mount bolts is a simple and smart idea, I'm glad you guys are on the ball, I might use that idea myself!

And in New Zealand where aerial topdressing was popular, a lot of the loaders were bedford  and ford trucks and typically they  had a great big hydraulic oil tank in the front of the truck with a direct drive off the crankshaft by way of a small universal direct drive shaft, to the tank mounted pump. They didn't use ALL the truck horsepower though, but were quite sizable all the same with good oil flow....never gave any problems that I recall.
Title: Re: Processor Build
Post by: North River Energy on July 10, 2014, 09:59:56 AM
Details on the dump valve referenced in post #7.  This particular cylinder has a 6" bore and 4" rod.

The parts.


 (https://forestryforum.com/gallery/albums/userpics/30352/dumpvalve1.jpg)


This is an older part number, as the shop had a bunch left over from an OEM project.  I think the valve itself was right around $95usd.


 (https://forestryforum.com/gallery/albums/userpics/30352/dumpvalve2.jpg)


3/4 line coming in from the right is cylinder extend, 1" hose at bottom is return to tank.


 (https://forestryforum.com/gallery/albums/userpics/30352/dumpvalve3.jpg)


Side view.  I should have upsized the cylinder port from 3/4npt to SAE16 when I resealed it...


 (https://forestryforum.com/gallery/albums/userpics/30352/dumpvalve4.jpg)


1/4 line picks up pressure spike at start of cylinder retract, this pilot signal unseats the dump valve allowing fluid to bypass the control spool. Again, could have resized the retract port for quicker action.  Still works as it should regardless.


 (https://forestryforum.com/gallery/albums/userpics/30352/dumpvalve5.jpg)


Return to tank.  1/2 inch line is unused return from the second pump stage.  This particular pump ran the implements and the power steering on a backhoe.


 (https://forestryforum.com/gallery/albums/userpics/30352/dumpvalve6.jpg)
Title: Re: Processor Build
Post by: Higgo on July 11, 2014, 03:00:51 AM
"Great what a man can do with some metal and a welder!"

Very true words! I actually had a lot of metal working machinery -cnc lathe, lathe, mill etc. but sold it all because I found I didn't use it near as much as I thought I would... The welder, torch, grinders and drill press seem to be the most used now! I also recently bought a small linsher belt/disc grinder. Small and cheap but very handy for de-burring and squaring up various pieces of the machine. Thanks for the comments and suggestions everyone! The pilot operated dump valve looks like a very good thing. I think  may have to get one of those... Has anyone done a regenerative style splitter system or have any experience with the prince auto cycle valves? North River, do you have any other photos of your machine or a build thread I've missed? It looks like a well built machine.

I've done some friction and load calculations for the conveyor motor. Came out as requiring approx. 3hp and  437ft/lbs of torque! However the formulas I used were based on using a log 19ft long and 24" dia. which has a density of 1040kg/m^3 green (blue gum, an Australian native plantation timber which has similar characteristics to sugar gum) meaning the log would weigh 3,858lbs or 203lbs per ft of timber. 
Then calculating the pull required for the chain and timber (203*0.33)*19= 1,286lbs= P
HP= (P*Speed of conveyor in ft/min)/33,000
therefore (1286lbs*65ft/min)/33,000
HP= 2.5
Tq= (HP*5252)/30rpm (the speed of my conveyor sprocket to give 65ft/min)
therefore Tq= (2.5*5252)/30 = 437ft/lbs
I've left a fair chink of the calculations out and my algebraic shorthand isn't that good! I've probably made a mistake but the figures seemed about right. Obviously I will need more than 2.5hp becaue my calculations are based on approximations and not actual figures... Sorry for the mix of metric and imperial  measurements... I just can't seem to escape imperial... every now and then it still creeps back in. Lucky Australia used to be imperial so I've always worked with both.
Anyone know the rough flow/pressure figures for there conveyor motors? Might be a good way for me to check my calcs. in the real world! I think I'll still use the jack shaft principle and the vane motor I have. Thanks again everyone for the replies and the pictures... They are really helpful!
I've done a bit more on the machine... had to change one thing slightly on the front because it made a weak spot that I couldn't really design around but not too much time lost. Got the saw mounted up (although it's not finished in the photos and also the oil tank (just temporarily). I intend to finish everything and give the machine a final once over before painting it so some brackets etc are only loosely bolted. heres a couple of photos...
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140710121804.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140709045426_28129.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140709045426_28129.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140710121853_28129.jpg)
Keep the comments coming... It's encouraging to know someone else is interested in my work!
Title: Re: Processor Build
Post by: johndeerkiwi on July 11, 2014, 05:13:09 AM
Re Prince auto return valves....I have a note in my diary somewhere that the prince auto return valves had a very modest maximum flow rating, and are not rated for higher flows. They are a good idea though, so I suggest you check the flow specs out, I think I accessed that info off the Prince site. If they prove to be too small, they are after all, only a double detent valve so it should be possible to make up a larger one.

Regeneration: Its funny that you should also mention regeneration, because it was regeneration that one so called hydraulic "expert" initially reckoned would not work, when I said I was wanting to use it to speed up my splitter cycle.
In fact he was the manager of a well known hydraulic company!!
But it does work, in fact, you just got to do it right. More commonly used in large "platen" presses where the large ram necessary to get the high pressure desired, made the approach speeds too slow. Regeneration overcome this problem.(there are several different ways of achieving the circuits)
So for any readers thinking "what the heck is regeneration?", simply put, a double acting ram is supplied with  pressure to BOTH ends at the same time (on the extension stroke), and it will still extend, in fact, it extends faster(but with less force).

Why does this happen?
Well, assuming a fairly normal  ram (say)with a 2:1  cylinder to rod ratio, (which means the cylinder holds twice as much oil as the rod end because of the size of the rod. (lets say 4 litres and 2 litres)
Under a regeneration system, oil is fed to both ends simultaneously. As the rod is forced to extend, the 2 litres of oil already in the rod end will flow out and into the other end, so instead of having to pump 4 litres to extend the ram, you only have to pump 2!(so twice as fast!)
However in a regeneration system, the oil in the rod end is pushing back, so this extra speed comes at a price.The speed has doubled, but because it is pushing back, the net force has halved. The extension is reliable though, because the oil able to push on the biggest area always wins.
So how do we then achieve full power when we need the full force?
Quite simply, we open a valve allowing the rod end oil to return to tank, simultaneously closing the pump oil pressure supply to the rod end.The ram returns to "normal" and can develop full pressure.
This process can be done manually (say with a double acting valve) or automatically, by using a kick down sequence valve set to trigger at a predetermined pressure.
The result is a ram that initially extends twice as fast at half the force, but when a predetermined pressure is reached the sequence valve dumps the rod end oil to tank, allowing the ram to  reach full pressure. Who said you cant have your cake and eat it too?
Title: Re: Processor Build
Post by: North River Energy on July 11, 2014, 09:26:23 AM
Higgo,
Nice tank.  Any ports on there for case drains?

Have not yet compiled the build photos from that particular machine.  A few clips of 'proof of concept'  here:
https://forestryforum.com/board/index.php/topic,75787.20.html (https://forestryforum.com/board/index.php/topic,75787.20.html)
Have a few details left to resolve, but works more or less as intended to break down the oversized that won't fit through my processor:
http://beckmannag.com/firewood-production/rebuilding-a-firewood-processor (http://beckmannag.com/firewood-production/rebuilding-a-firewood-processor)
Need to update that page, as I have done a few more upgrades since, including a larger saw drive motor, lowered tooth count on the blade, and single lever auto cycle actuation.

No experience with the Prince auto cycle valves, but the DanFoss auto cycle valves will take a little more than 25gpm without difficulty.  With a 4" bore, 2.5" rod, 27" stroke and the dump valve setup, the cycle time is more than adequate, and I'm not using maximum pump/valve flow.

Maybe I'm cursed, but the standard Prince valves seem to leak prematurely out the back of the spool for no particularly good reason.
Pump flow to the infeed drive motor is right around 10 gpm, but as mentioned previously, my chain driving cog is much smaller than what you will be using.
As to regeneration, that option seems to come up on 'economy' splitters to make up for the mismatch of a tiny pump and larger cylinder.
JDK, did you actually employ this principle, or was it mostly theoretical for your application?
Title: Re: Processor Build
Post by: dave_dj1 on July 12, 2014, 04:30:49 PM
Looks really good so far! Nice work.
Are you going to put flat stock on top of your infeed vee? I see lots of potential for snags if you don't.
Keep up the good work and keep us posted.
dave
Title: Re: Processor Build
Post by: Higgo on July 13, 2014, 02:32:56 AM
Good info! Thanks everyone.
dave_dj1 I do have panels for the conveyor sides just haven't got around to fitting them yet! Had them guillotined at a local steel shop so that are ready to fit and weld in (3mm mild steel 1200mm by 480mm). I've got some stuff on at the moment so it might be a while before I can spend some time on the machine again. N.R.E. The oil tank does have a case drain port and also a large return port... also 2 large suction ports and 1 medium side suction port so it should hopefully do the job. I'm a little concerned it might not have the thermal capacity required for the amount of oil I'll be moving so I may need to plumb in an oil cooler, however I'm going to wait and see before I source one. To be honest I think it will almost definitely need a cooler! The tank came from an old garbage truck and even had clean oil in it! I drained the oil however... might use it in one of the old tractors or trucks around the farm rather than re use it in my nice new machine. I need to do a couple of welding jobs on the tank and luckily it has a couple of inspection ports I can open up to vent it. I was thinking of filling it to the brim with water to be on the safe side. Won't be doing that for a while yet though. Another question...does anyone have some details on the valves they use with Danzco saws? Just interested to see what other people are using. Thanks for the suggestions everyone.
Title: Re: Processor Build
Post by: North River Energy on July 13, 2014, 09:04:10 AM
While you have the tank apart, add a few more return ports with submerged piping.  You never know when you might need one.
And definitely plan on a the cooler. That tank has the right shape to cool under 'periodic use' conditions, but you're building the kind of machine that should be able to run all day.   A larger volume of fluid will take longer to heat, but it will also take longer to cool.
Title: Re: Processor Build
Post by: Higgo on July 13, 2014, 10:21:18 PM
Thanks for the good idea. I think I will add a couple of extra ports. The larger ports are welded into the inspection holes... more of an 8 bolt flange about 8" dia. from memory it can sort of be seen in one of my previous posts. I will probably just unbolt one of those and add a couple of ports to it. I missed out on the perfect oil cooler a while back... might have to start hunting. A thought... what about an old oil heater/s radiator? might be able to braze some ports onto one of those? would certainly be a 'feature'!

I've added a photo the jig I used to assemble the 'dog legs' of the conveyor. I used a similar one to cut the pieces and this one picture to assemble and tackweld them together. I always try to do things this way... seems to make neater products!
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140711104010.jpg)
Title: Re: Processor Build
Post by: North River Energy on July 14, 2014, 08:29:32 AM
Re: oil cooler. I'd haunt the local breakers for something off a track hoe or similar. 
The oil heater's designed for a slower steady release, rather than rapid dissipation.  Would work better than nothing, but...
Title: Re: Processor Build
Post by: dave_dj1 on July 14, 2014, 10:04:06 AM
Looks good Higgo, I figured you were going to have a solid deck.
Keep the updates coming.
dave
Title: Re: Processor Build
Post by: Higgo on July 14, 2014, 09:29:34 PM
Good point on the oil coolers. I'll begin my hunt for one again! anyone have a good suggestion for surface area/port sizes or one that works well on their machine? I've found some cheap industrial ones on ebay but they still look small... the port size were around 32mm (more probably 1 1/4") I don't think the guy knew too much about the products he was selling. I guess I need to find some heuristic formulas for oil cooler size/pumped oil volume? Some machines I worked on used 'offline oilcooling/filtration' to save energy. Only pumped the oil to the cooler when needed and therefore only filtered when needed. Seemed to work pretty well. The oil was so clean that it lasted around 5 years between changes... and these machines ran 24/7. I was thinking about using a similar principle using a diesel transfer pump... small, cheap and not power robbing. Anyone used a similar setup? Probably overkill.
Thanks dave_dj1! Getting there slowly... only another 1000 hrs of work and I might be done!
Title: Re: Processor Build
Post by: North River Energy on July 15, 2014, 08:51:16 AM
Go big on the cooler ports if possible. You can always bush them down. 1-1/4 should be more than adequate. 
My cooler is maybe 16"x16" with 1" ports, and it does the job, though a better fan would help. 
And that's with a circle saw, which makes a lot of heat.
I'd continue to build out the machine to the 'proof of concept stage' without the cooler (if one proves elusive), but provide for the later addition.  Your tank has the optimum shape for passive heat loss anyway, and if you minimize the flow restrictions in the rest of the system, you might be fine for the short term and short duration use.
Title: Re: Processor Build
Post by: blackfoot griz on July 15, 2014, 09:39:49 AM
I agree with NE. I would try it without a cooler and watch the fluid temps.  If they are getting too high, you can add a cooler.  If you will be running the machine in cold weather, I would suggest a cooler with a thermo switch so that the fan on the cooler only kicks on when the hydro fluid hits a certain temp. If it is cold out you may not want the cooler/fan operating.

I don't have a cooler on my processor and even running the thing as hard as possible on a HOT day, the hydro fluid has only gotten up to 150.

Thanks
Title: Re: Processor Build
Post by: Higgo on July 15, 2014, 09:05:24 PM
Good points. Blackfoot, I think my machine will have a similar capacity re-oil flow to yours? I think I read somewhere you have around 50gpm capacity?  I'll continue without the oil cooler at the moment and try running the machine without one and see what temps the oil reaches. The cooler I was talking about earlier is pretty cheap so if I can't find a cooler secondhand I can always just buy it new. It's not looking like I'll be able to do any work on the machine for at least another 2 weeks at the moment... just when I was making some good headway!
Title: Re: Processor Build
Post by: Higgo on July 17, 2014, 12:17:38 AM
I forgot to put a photo up of the saw mount! It's a little hard to see and not quite finished but its in the spot it will stay. I've got to add a little bracing around the saw base plate mount but overall its pretty strong anyway.... might try and incorporate an area to run some hoses for the saw neatly within the base mount. I'll post another photo when I'm next working on the machine because I slightly altered the left side bearing mount. Any ideas/suggestions feel free to post them!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140710054600.jpg)
Title: Re: Processor Build
Post by: North River Energy on July 19, 2014, 12:14:58 AM
Griz,
You've had your machine up and running for a few years?  Have you made any additional modifications in that time, or are there things you wish you had done differently?
Title: Re: Processor Build
Post by: blackfoot griz on July 19, 2014, 12:33:20 PM
NER,
I guess I got pretty lucky when building my processor. I had some help from FF members and some local folks in the configuration. From the first time I fired it up to now, the only thing I changed was that I added a flow control on the detent valve for the conveyor.  It ran way to fast. Now, I can slow it down and run it just fast enough that the split wood doesn't build up.

The one thing that really surprises me is the chain oiler I threw together.  I used a radiator overflow tank. It holds about 1/2 gallon. From there, the bar oil goes to a napa fuel sending pump. I added a flow control valve after the pump.  On the 1"shaft that the saw is mounted on, I mounted a napa pickup "cablight door switch" and welded a tab on the shaft.  When the saw is all the way up the tab hits the switch and cuts the electrical flow off to the pump. This is handy when you get sidetracked and don't need the bar oil to flow.

The whole oiler system cost about 70 bucks and I was sure there were going to be problems. At the time, I got in a big hurry because my dad was terminally ill and he really wanted to see the processor work so I winged it on the oiler. To my surprise, this setup has worked amazingly well. It goes from no oil to way too much. I have even pushed "summer" bar oil through it when it was 0 degrees out and it works fine.

Considering I am only running a 38 hp Kohler @ 2400 rmp, it works really well. Now, I find that I spend much more time dealing with the split wood than running the machine!

Title: Re: Processor Build
Post by: North River Energy on July 20, 2014, 12:10:24 AM
^Thanks.

QuoteNow, I find that I spend much more time dealing with the split wood than running the machine!
Most days I figure the material handling at either end is more crucial than the machine in the middle.

Have the same NAPA/Facet pump on several machines for several years.   No complaints so far.

Any idea on your fuel/hr/cd?
Title: Re: Processor Build
Post by: blackfoot griz on July 20, 2014, 09:35:39 AM
It takes 15 minutes or less to fill an 8'/full sized pickup box so I'd say that the processor is capable of producing  2 cord/hour +/-.

I stack my firewood on pallets and it takes 1/2 hour or so to move the split stuff from the pickup to the pallet. Working by myself, I have processed 10-4x4x4' high pallets in a day which = about 5 cords processed and stacked. With each passing year, this will likely drop. Fuel consumption?... I run a pickup load then shut it down while stacking. 10 gallons of gas will easily go all day, but the processor is only running less than half the time.

The stacking part is the killer in my situation.  I have been considering making some bags for the pallets. This would be a lot faster, but, you end up using a lot more pallets for the same volume of wood which takes up more space and makes more trips during the burning season. I haven't come up with the perfect solution as I don't think there is one  ???
Title: Re: Processor Build
Post by: Higgo on July 21, 2014, 10:20:48 PM
I can see how dealing with the split wood would take more time than actually processing the stuff in the first place! I plan to deal with it in 'bulk' using front end loader bucket or a small excavator to handle the raw logs and the split wood. One operator running the machine and one operator driving the loader. We don't generally handle wood here where we need to stack it. Maybe you could look into 'bulka bags'? We use them for fertiliser and seed grain but they're pretty tough and might be good for your handling needs. One bag can hold 1 ton of material... So probably about 600kg of wood... and you can move them with a forklift or loader with the lifting eyes! I like the idea of the flow control for the conveyor. I have an old flow regulator so I'll try and incorporate that idea into my build.
Another question... my engine doesn't have a governor fitted because its a truck motor. Has anyone developed or setup a governor system on their processor? I've toyed with the idea of using an aftermarket cruise control kit but I'm curious too see what other people have done and what their thoughts are...
Title: Re: Processor Build
Post by: dave_dj1 on July 22, 2014, 06:36:42 AM
The last processor I looked over was a Timberwolf with a deutz 3 cyl diesel and all he had was a throttle cable that you pulled out and locked. I have heard they sell electric governors but have no experience with them.
good luck,
dave
Title: Re: Processor Build
Post by: North River Energy on July 22, 2014, 05:44:13 PM
BGriz,
I added an hour meter to the panel as an afterthought, and have found it to be very helpful in determining costs, throughput etc.
Can't help much on your stacking quandary, as I leave that up to the end user(s). :)


If the Deutz was intended as a stationary, the governor is incorporated into the injection system, with the throttle cable setting the baseline rpm.
Higgo, if your motor type has use as an off the road power plant, the simplest option would be to locate the appropriate original equipment governor?
The cruise control idea sounds interesting.  How do you propose to measure speed and move the throttle?
(The cruise configurations I'm familiar with use vacuum/dashpots.)

I'm going to try a variant of this hydraulic throttle control on my 'new' big splitter.


 (https://forestryforum.com/gallery/albums/userpics/30352/hydrothrottle1.jpg)


 (https://forestryforum.com/gallery/albums/userpics/30352/hydrothrottle2.jpg)



The donor unit in its current application. (Not really needed on this truck).

 
(https://forestryforum.com/gallery/albums/userpics/30352/hankhydrothrottle.jpg)

And a constant speed belt drive governor.  Not very adjustable, more or less on or off.


 (https://forestryforum.com/gallery/albums/userpics/30352/constantspdgov.jpg)
Title: Re: Processor Build
Post by: Higgo on July 22, 2014, 09:36:51 PM
I have tried to find the OE governor but have had no luck so far. I might try and contact Mazda and see what they think. From memory even the parts manual doesn't show much. The cruise control kit does work like you say. I would have to retrofit the diaphragm onto my injector pump. That belt drive governor looks interesting... what did it come off?

I like the idea of a hydraulic governor. On my machine I intend to eventually have the whole thing 'driven' by PLC. I could probably use the plc to govern the engine with a secondhand cruise control servo from any vehicle. To be honest I will probably go down this route because the PLC is capable of doing it and will already be supervising other functions (that's if I can't find an OE governor). Thanks for the reply NRE. very interesting ideas! The hydraulic governor is something different I hadn't considered before! The cheap aftermarket electronic cruise controls setups can be had for around $200 so I thought that was an interesting option. How much is a hydraulic governor setup worth?
Title: Re: Processor Build
Post by: North River Energy on July 23, 2014, 09:20:35 AM
The belt drive was original to my processor with the original gas motor.  That type was apparently common to Jeep vehicles for use around the farm way back when. (I'll get the name off the data tag and you can find some history).  The way it was rigged (not my doing), the engine would start full throttle, and shut down full throttle, with nothing in between.

I don't know that you'd be able to buy a new hydro-throttle. That schematic is dated 1967, when one might power a log truck off either gas or diesel. 
From the look of things, it would be easy enough to make your own. 

If you're aces with the electrics, you could pick up the rpm from the alternator (diesel rated), translate the signal to something useful, and send that to a small stepper motor to push/pull the throttle linkage.

Some of the old gas-drive mills controlled speed with something like a license plate swinging in front of the radiator fan airflow. A variant of the fly-ball principle.

You will probably have enough HP/torque on tap that you can run at a set rpm just a bit above idle. 
At least for the trial runs. 
And then you want to figure out how to save fuel and noise...
Title: Re: Processor Build
Post by: Higgo on July 27, 2014, 10:57:38 PM
Thanks! Some very interesting things to think about! I think I've seen something like the licence plate idea on another old machine somewhere... can't remember where though! I've been making a bit of a plan up for when I can work on the machine next. I'm away from it at the moment because the shed where its kept is not near my home.

Another idea for everyone to think about...
I've already built a large splitter that I intended to mount under the front so the wood could fall into the splitter chamber however I'm thinking I might leave it separate for a while once I get it built. I think I may be better off building a smaller splittter specifically for the processor and leave my nice larger one for conventional splitting. I'll try and put some pics of the splitter up next time I'm at the farm. I think it would make a nice 3pl tractor splitter or even a towed splitter compare to shoving it under the front of the machine. It's built from 12" C section welded back to back and has about 40" of stroke... too much for a processor but good for big rounds of redgum. I built it before my processor construction started and I originally intended my processor to be a gas chainsaw/conveyor splitter setup... Its not quite finished (needs the wedge made up).

I guess everyone knows how ideas evolve! :D
Title: Re: Processor Build
Post by: Higgo on August 14, 2014, 12:23:29 AM
I know everyone has different opinions on this but.... what sort of splitter wedge material should I go for? I'm leaning toward mild steel at the moment... seems a lot of people just use mild steel and it works for them. Feel free to post suggestions and pictures of your splitter wedges. I think my wedge will be an adjustable 1/2 to 1/4 split.
Title: Re: Processor Build
Post by: Higgo on August 20, 2014, 09:37:54 PM
Finally got a chance to do some more work on the machine over the weekend! Cleaned and primed the underside of all my in-feed conveyor panels with grey primer before welding them in. I also primed the underside of the square tube where the panels sit flush on the tube. I've noticed a lot of manufacturers of other machines do a similar thing. This should hopefully slow down the advent of rust... although I realise its inevitable in a design such as this where the panel is sandwiched against the square tube. I think i'll try and seal the panels with some type of silicon as an added deterrent to moisture penetrating the seam. I also welded the chain guide in place onto the spine of the machine. I used 12mmx12mm square stock and welded at 150mm intervals. The panels are welded at 100mm intervals because they are thinner material and I felt it would distribute the shock loads better. I haven't welded the underside of the panels because I think it would make it very difficult to replace the panels at a later date... however I am tempted to weld the panels on the underside! How are everyone elses machine constructed in regard to the in-feed conveyors? panels welded underneath? I've also taken a lot of photos of the valves and motors I have. I haven't posted them up here because In not sure if i'll be using them yet. It's mostly just left over components form previous jobs.

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815013402.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815030224.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815030618.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815045712.jpg) 

 (https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815045741.jpg) 

 (https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815051734.jpg) 

 (https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140816022956.jpg) 

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815051829.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140815051734.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140816031714.jpg)
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140816054345.jpg)
Title: Re: Processor Build
Post by: North River Energy on August 20, 2014, 10:52:54 PM
Regarding wedge material, all three of my splitters have common steel.  So far it's not a problem, but you might want to design your wedge such that you could easily change it out if you feel the need for a re-work.

As to the infeed, mine has two large pitch chains (80+) running parallel on an oaken platform.  I'd prefer a roll case, but it's what I have at the moment, and the need to change that part of the machine is quite a ways down on the 'fix-it' list. 

I'll get a photo in a few days time.
Title: Re: Processor Build
Post by: xalexjx on August 21, 2014, 06:04:47 AM
have you designed the wedge setup yet? I have a built rite with a 4way on the bottom and 6 way on top all hydraulically controlled. I can post pics if you want.
Title: Re: Processor Build
Post by: Higgo on August 21, 2014, 07:46:38 AM
thanks for the replies! It would be great if you guys could post some pics. There's not many machines around here to borrow ideas from! If anyone could post some pics of their wedge design and maybe a vertical pic so I could determine the correct angle? there must be an angle that is 'best' suited to a splitter wedge and specific materials? I hope to make it a 2, 4, 6, 8 if possible. I haven't built the splitter I intend to use with this machine. The original splitter I built for it I think I will use as a stand alone unit... so I'm back to the drawing board for the splitter!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on September 13, 2014, 03:19:07 AM
I attached a couple of 'action shots' of me welding the conveyor side panels.

Anyone have any suggestions/photos regarding the design of a 2 4 6 8 wedge?? I'm trying to decide how to make it adjustable and multi-split all using the 'same wedge' like the commercial processors that use a cylinder/ 2 cylinders to adjust the wedge/s. Post some photos of your design if you want!!!   ;D

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140816051413.jpg)


(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-20140816051357.jpg)


Title: Re: Processor Build, Home Made Firewood Processor
Post by: TeaW on September 22, 2014, 12:37:20 PM
I don't think there is any right answer to the question of splitting wedge design. It depends on the size of wood you have to split and the size of pieces you want to make. I had a friend that had a Multitech processor , he had 4, 6 and 8 way wedges. He liked the 4 way the best because he thought he had more control of the size and got less splinters.(he threw big stuff back through when he had to). Another operator that built a few processors would only us a star shaped wedge ( all pieces starting in center).
For myself the best size is 10" split 4 ways, but that means that a 20" log needs to be split into about 16 pieces. It is hard to have one wedge that will do it all, I guess you have to go with what will suit you.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on September 24, 2014, 08:02:04 PM
Thanks TeaW. I think I'll have to study Youtube for a few more hours and see what I can come up with! What thickness steel is your wedge made from? I'm thinking around 3/4"/20mm is what I'll try to construct mine from.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Hilltop366 on September 24, 2014, 10:26:30 PM
Nice work on your processor build!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: North River Energy on September 26, 2014, 08:43:32 AM
You've probably seen this one, but it's a variation on the multi-wedge theme.

http://youtu.be/M0FVh99ytIg (http://youtu.be/M0FVh99ytIg)

Go with a wedge configuration that best suits your feedstock, market demand, and hydraulic capacity.
(2 and 6 works well for me, but might not for you.)

Design for something interchangeable, to avoid 'welding yourself into a corner', so to speak.


Title: Re: Processor Build, Home Made Firewood Processor
Post by: beenthere on September 26, 2014, 09:46:29 AM
Appears to work pretty well.. at least the guy at the controls can keep things moving. Didn't see much of the multi-wedge design and how it works.

Not an easy video to watch with the camera operator trying to capture everything by panning so fast from one thing to another.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: r.man on September 27, 2014, 07:29:45 PM
That is the third or fourth time I have watched that video and at least two things come to mind, that operator is really good and some of it should be automated. Carpal tunnel syndrome and all sorts of other nasty repetitive stress problems come to mind not to mention the loss of production when operator # 1 is off for a few days. Splitter frame could be linked to clamp height and the splitter should be auto cycle with a trigger plate. For that matter the whole cycle could be auto with the operator having to load logs and troubleshoot.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Peter Drouin on September 28, 2014, 06:49:19 AM
Now that is a nice one, Very good job you did,  :)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on September 28, 2014, 11:22:21 PM
Thanks for the suggestions everyone. I like the idea in that video! I'm pretty sure I've watched it before (as well as the other hundreds of videos I must have watched trying to gather ideas!). On a large lathe I helped retrofit a couple of years ago I used a hydraulic turret from an okuma cnc with an adapter plate to bolt to the original cross slide; worked well and is very similar in principle to the idea in the video. Might have to put pen to paper and draw a couple of designs up. I haven't been able to do much work on the machine lately... hopefully in 3 weeks time I'll have about a month straight to work on the machine... should get a reasonable amount done. The goal is to finish the machine by the end of the year. I might be getting a little ambitious!!!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on October 08, 2014, 03:35:10 AM
Just a picture I found on my old phone of the last of an old redgum... just the stump. A bit off topic... I did cut about 4M^3 out of the one log though! Funny thing was as I was cutting it I started to notice a line of carbon down one of the veins inside the log. I asked around and concluded that at some stage the tree had been hit by lightening! Wish I'd taken a photo of that part now... The axe in the photo is the reason I started building the processor! Cut this with a 365 Husky with a 20" bar and used the axe to split it all. I've been told they can live to over 1000yrs old. I should ad this one had already fallen over and was in the middle of a cropping paddock. I've posted the wiki link if anyone  is interested on reading up on Eucys! http://en.wikipedia.org/wiki/Eucalyptus_camaldulensis

(https://forestryforum.com/gallery/albums/userpics/36796/2012-08-26_11_53_45.jpg)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on January 09, 2015, 01:23:10 AM
Finally got around to doing a little more work on the machine. The main in-feed conveyor is effectively finished now... just requires final welding. I intend to remove the entire frame from the chassis with the front end loader and rotate it as I weld it up fully, to avoid having to do mostly overhead and vertical welds. I would normally just weld the pieces in-situ, however because there are so many welds I feel it may be easier. Added some side braces to the conveyor which I cut on my horizontal bandsaw to maintain the correct angles. I then tacked the braces in place using a jig to ensure they were square and in the same position (far easier than measuring each one individually) I've attached a photo of the jigs I've used so far to help with the build. I also welded the last of the conveyor panels in place. I think there are 320 stitch welds in the panels alone! Hopefully mount the pump and valve blocks soon and try and rebuild my splitter to suit the smaller place it has to fit into. Any suggestions or comments are most welcome!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--6921433438159801988.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--7484667191996723722.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-4621627621499837102.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-7648108462932577533.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--5371208616871450850.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--5420292225956530026.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-7822770913423243441.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-158945284691182929.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-4227989401041204964.jpg)

Any comments or suggestions are most welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: TeaW on January 09, 2015, 07:47:46 AM
Glad to see your back at it. Look forward to your progress.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: DeerMeadowFarm on January 09, 2015, 09:25:38 AM
Looking good! I like the clever jigs you came up with.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on January 14, 2015, 05:15:40 AM
Thanks for the feedback! Today I began mounting the hydraulic pump drive. The pump will be driven from the back of the truck gearbox into a divorced NP205 transfer case that is mounted backwards... by that I mean that the old rear axle output is now the input... and also means that there are 2 'output' yokes on the 'back' of the case (facing to the back of the machine). This means that with the transfer case in 2WD mode only the pump will be driven. In 4WD mode the pump AND rear axle will be driven. This set up should allow me to move the truck under its own power. I had thought about going trailed/ hydrostatic drive but at this point in the build I felt the machine was almost too heavy to be safely towed with a ute and so have opted to keep the trucks running gear intact. If it doesn't work out I can always go down my original plan of hydrostatic drive. I still hope to be able to tow the machine on the highway because in this configuration the original truck front axle remains... therefore carrying the weight of the machine instead of putting a lot of the machine weight onto the hitch of the tow vehicle. The pictures should help explain the gearbox process a little better. I did have some concern about running the transfer case in reverse but it was taken from a much more powerful truck so 'should' be able to take the load even whilst running in reverse. I know that the NP205 cases can be altered to run in this configuration (backwards) however I don't particularly wish to alter the case if there is no pressing need. I intend to run the transfer case to destruction (which is hopefully never!!!) before altering anything from 'factory'. If anyone has done the NP201/205 modification I would like to hear from you regarding the procedure/results of the modifications. Comments and feedback are welcome!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-3164930412868194015.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-8105991284735928430.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--120073784280124188.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-4665058997006457507.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--7241741167875297075.jpg)

Comments and feedback are welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on February 07, 2015, 11:02:53 PM
Did some more research on the transfer case I'm using and apparently it can be 'twin sticked' very easily. Doing this should allow me to run the case in the normal direction and still achieve the drive configuration I want. The procedure is exactly as in the website here:

http://4x4mecca.com/forum/vbarticles.php?do=article&articleid=32

Edit: I have just completed the modification as described above and it seems to work well! I'm going to pick up my modified drive shafts tomorrow so should be able to fit it all up. Next component is the hydraulic pump mount. Not very interesting but it allows me to select hi, neutral or low for each output individually.

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-1472198071997199905.jpg)

Title: Re: Processor Build, Home Made Firewood Processor
Post by: DeerMeadowFarm on February 09, 2015, 10:49:01 AM
I have a twin stick configuration on my truck that I am building. You need to be careful when grinding the shafts or you can find yourself in a situation where you can shift into two different ranges. Probably not as important in this project but it would cause serious issues in a 4WD truck!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on March 09, 2015, 11:23:55 PM
Got 2 of my modified drive shafts back last week. I've mocked up the transfer case I'm using but ran out of time the other evening so didn't get any welding done. Below are some pics of the new drive shafts. I'll try and get some better pictures once the transfer case is installed.

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--6003552698914002630.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--1573507816607102001.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-817377994597625973.jpg)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on April 15, 2015, 08:13:45 AM
Started to fit the transfer case into the chassis rails on the weekend. The fitting has taken quite a bit longer than I estimated being that it's a very confined space and difficult to work with a heavy large gearbox! I fabricated a new mount for the transfer case and did the trigonometric calculations to determine the angle the case needed to be 'laid back' in order for there to be zero angular displacement of the drive shaft (no bends!). I measured along the head of the engine at two points to the 'spine' of the conveyor vee; then measured the length of the cylinder head; did the calculations and voilĂ ! 2 degrees of tilt to eliminate any bends in the input shaft. When looking at the engine gearbox of the original truck it doesn't appear to be much of an angle at first but over 2000mm or so it adds up to a resonable amount of drop. I did all this because the input shaft only has one universal joint and is quite short ~400mm. The shaft also has a rubber flex disk at the opposite end which calls for precise angular orientation else the disk should fail due to fatigue. Hopefully photos of the transfer case fully installed at a later date better explain. Feel free to comment with suggestions!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-5686223853845323313.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-947630955318500655.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-666614299178347275.jpg)

Comments and feedback welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on April 15, 2015, 10:35:46 PM
I like the fact you recycle stuff, that keeps the cost down. smiley_thumbsup
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on April 28, 2015, 01:12:59 AM
Haven't had much time at all to work on the machine lately. Hopefully get a couple of weeks of work done in around 5 weeks time. In the meantime I did buy a small machine to help cut steel profiles which should hopefully make my work look bit more 'polished'. I occasionally make other projects so I'm expecting it will be of help there too. It's not set up yet so there's no table at the moment. I'll post a picture... see if you can figure out what it is/how it works....

(https://forestryforum.com/gallery/albums/userpics/36796/__12.JPG)

Any comments or suggestions are most welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on April 28, 2015, 09:40:27 PM
Is that a acetylene cutting torch ?  I think you have to do some explaining. :) 
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on May 07, 2015, 07:35:54 AM
Correct! It's an oxy cutter pantograph/template tracer depending on the name people use. I'll post some pics and a video when I start using it.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on May 17, 2015, 08:27:09 AM
Had the time to do a little more work on the weekend. Still quite busy at the moment so only managed about 5 hours work. Got the drive shafts roughly mounted to check hydraulic pump location then made the SAE C 4 bolt mount out of some 10" C section that I cut with my band saw then drilled with my drill press and really big hole saw 5" !!! I figured this was cheaper than buying a ready made mount. The hole saw was $80 which I think is cheaper than it would have been to have someone bore the hole for me. I was quite happy with how it turned out. The holes on the the flanges are to bolt the flange mount to the chassis. I'll fabricate some hangers to bolt the flange mount to. Comments and questions are welcome!

(https://forestryforum.com/gallery/albums/userpics/36796/1431753784191.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/1431756467556.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/1431757800342.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/1431757930566.jpg)

Comments and questions are welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: North River Energy on May 17, 2015, 10:31:48 AM
Thanks for the update.
Before I had a slug cutter/trepanning tool, I used to drill at least two smaller holes (180 apart) at the periphery of the main hole.  Hole saws generally don't have enough chip clearance for thick stock, and those two holes provided an exit for the chips so as not to pack the gullets. 
Cleaner and faster than periodically clearing the kerf with compressed air.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on May 17, 2015, 12:21:25 PM
I always find it tricky to get the flange holes lined up, but it looks like you're right on the money. smiley_thumbsup
I know, I am just a amateur. ;D
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on May 18, 2015, 12:46:43 AM
NRE that's a good practice for hole saws. My drill press is pretty underpowered for a 5" hole saw so I just peck drilled it very carefully... Normally I do drill clearance holes and I probably should have in this instance.

My two cents worth in regard to laying out holes:
Anyone who regularly drills holes that need any degree of accuracy should invest in a height gauge. Mine is one of the most used tools in my shop. It's amazing what can be achieved with a height gauge and trigonometry. Even for drilling grids of holes I consider it almost essential. Many people have commented over the years about my height gauge and I guess it's because they are a tool which you only come across if you've worked in industry???. Can I suggest that anybody who hasn't heard of or seen one before watch a video or read up about them. Literally one of the handiest tools per dollar I own. Mine is a mechanical digital Mitutoyo type hence no batteries! I've attached a picture of one similar to mine

Thanks for the comments everyone. Keep the suggestions coming!

(https://forestryforum.com/gallery/albums/userpics/36796/height_gauge.jpg)

comments and suggestions are welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: North River Energy on May 18, 2015, 08:43:32 PM
I remember pecking a three-inch hole through a chunk of one-inch plate on a similar drill press.  Probably took at least an hour...
Manual layout and execution is likely headed toward 'endangered' status.  Lots of satisfaction though when you hit the target dead-on using simply mechanical principles, and basic tools like spotters, transfer punches, wigglers and edge finders.

Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on May 18, 2015, 09:23:32 PM
Sweet, now I wish I would know how to run or read this nice little tool . ;D
Title: Re: Processor Build, Home Made Firewood Processor
Post by: North River Energy on May 18, 2015, 10:02:53 PM
^A quick overview.
https://youtu.be/-oSKiVioFws (https://youtu.be/-oSKiVioFws)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on June 26, 2015, 09:43:22 PM
Not much progress as of late. I did make the hydraulic pump support cross member/hanger and fit it into the frame. Below is a photo before it was welded into the frame. Mechanical work on the machine is nearly complete now, hopefully this week some time I'll be able to finish the remainder of the frame and begin work on a simple operator cabin. I've included a photo of the valve I intend to run the saw from. Bosh Rexroth 4WEH22; which should easily handle my requirement of 30 gpm for the saw. I have a few valves and left overs from other jobs that I'm going to try and use up. Hopefully I'll have some more interesting updates this time next week. Thanks for reading! Comments and suggestions are welcome!

http://www.boschrexroth.com/country_units/america/united_states/sub_websites/brus_brh_i/en/products_ss/10_standard_valves/a_downloads/re24751_2008-08.pdf

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-7620132535403149853.jpg)

VALVE
(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--6715161490831070226.jpg)

Comments and suggestions are welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Oliver1655 on July 10, 2015, 12:19:45 AM
Looks Good!  Keep the photos coming.

I guess I am lazy.  I would have drilled the large hole first then used a transfer punch to mark the flange holes after inserting the pump into the large hole.  A whole lot less brain strain for me.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on July 11, 2015, 06:34:33 AM
Made the motor mount for the in feed conveyor today. Managed to spend a couple of hours working out shafts/bearings for the conveyor chain and drive; I'll get those ordered so I can assemble the conveyor. Fitted a new water pump to the engine today as well... I've had the new one in a box for over a year so I thought I had better fit it!

Couple of photos of the conveyor motor mount:

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--4726572992785154248.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-1212204445101310431.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-4180339532048949332.jpg)

Comments and Feedback are welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on July 12, 2015, 01:58:11 AM
Quote from: Higgo on May 18, 2015, 12:46:43 AM
because they are a tool which you only come across if you've worked in industry???.

ok, I know I havn't, so I am exused.   I am just amazed about the accuracy how you cut those holes  smiley_thumbsup
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on July 29, 2015, 08:17:26 AM
Thanks for the compliment! The height gauge certainly makes a difference in regard to layout and overall part quality.

Today I laser cut some test sprockets for my conveyor drive. The used sprockets that came with my chain appear to be slightly incorrect in pitch.... Very annoying!!! To add to the frustration the conveyor chain I bought second hand is S45 agricultural chain. No big deal except that it has a pitch of 1.63" so sprockets only come in certain sizes. Used solidworks and a program called sprocketeer to create the DXF files necessary to cut my specific sprockets. I then cut some test 'templates' from perspex exactly the same sizes as if they were cut from steel. Took about 5 mins total to cut them all from start to finish. This way I'll be able to test the fit up and clearances before I get the sprockets cut at a local laser cutter. I'll buy the weld-in hubs to suit my 1.5" shafts and the 3/4" conveyor motor shaft then weld the hubs into the sprockets. I also intend to get a couple of quotes from local sprocket places to compare and if the costs are prohibitive for the larger sprockets I'll make them myself instead of buying them... (I have a feeling that the quotes might run into the high hundreds of dollars)

The conveyor chain sprockets are 40 tooth skip pitch 1.63" approx 11" dia.
Conveyor drive sprockets are 9 tooth ANSI 60 (about 2.5") and 63 tooth ANSI 60 (about 17.5") respectively, gives a 1:7 reduction ratio.


I was very tempted to give my pantograph cutter I posted previously a try using a perspex sprocket template but unfortunately the 'cutter comp' is larger than the tooth profile.... might make for some odd shaped tooth profiles!

I'll try and get some quotes soon and should then be able to decide which path to proceed down.

I might even get the height gauge out again and try marking out and drilling the sprockets manually!...... :D

I attached a photo of all the laser cut templates (it's hard to photograph something clear!).
If anyone knows how to embed an MP4 video using the gallery option here can you post/link the instructions?
(I only ever seem to notice youtube etc vids so maybe there's no option to embed?) I have a short video of the laser cutter in action.

Comments and questions are welcome!
See if you can guess the function of the square holes in the conveyor drive sprocket....

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--3066455934818646319.jpg)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: beenthere on July 29, 2015, 11:21:23 AM
Think just putting the video on YouTube and linking to that is the way to go. Much simpler, and apparently less server used up for the Forum.. if I understand correctly.
Interesting build. Keep us posted.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on July 29, 2015, 06:28:56 PM
I've uploaded the short laser cutting video to youtube. It's not spectacular footage but I thought some of you may find it interesting.

https://youtu.be/qscI0j-fZ34

Comments and questions are welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: North River Energy on July 29, 2015, 06:44:55 PM
So today I finally wired in my new/used bigger better milling machine.

Then you play the laser-cutter card.
Cheater. :D

Ahead full!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on August 03, 2015, 03:38:51 AM
Tried out the sprocket templates over the weekend... I must have done something right because they all fitted perfectly!!! I've sent my DXF files off to a laser cutting firm for a quote, so hopefully, if they respond with something reasonable price wise, I'll have them cut. That should get the conveyor/conveyor drive completed.

After many years of grinding rusty steel, I bought a cheap sandblasting cabinet to clean up some parts. I forever seem to be working with used steel and was getting pretty tired of grinding 10 or 12 small pieces to clean them up before welding. The cabinet should speed the process up a little.

Incase anyone is wondering in one of the photos you can see a close up of the tooth profile. The chain I'm using  is 'skip link' S45 agricultural chain meaning the pitch is 'doubled' and a link is therefore skipped.... hence the 'empty' tooth.

I've included a couple of photos for interests sake. Comments and questions are welcome!!!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-6323622843516689040.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-7957664613749574269.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-7082922383878732486.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--8533109353969269979.jpg)

Comments and questions are welcome!!!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on August 05, 2015, 06:54:13 AM
The local laser cutter shop replied with a lower than expected quote for my sprockets (about $170 AUS). They'll be using one of their plasma cutters to cut the sprockets from 12mm and 20mm HA250 plate. If I ever wear the sprockets out I'll just get them re-cut.  Hopefully they'll be ready to pick up next week sometime! I've decided to buy the small conveyor drive sprocket, by the time I priced the weld in hub, plus cutting, I could get one locally at a lower cost. Comments and feedback are welcome!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on August 10, 2015, 11:57:46 PM
Update
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on August 30, 2015, 04:41:35 AM
Received the weld in sprocket hubs in the mail but haven't had much time to work on the machine lately. Hoping to have a bit more time a couple of weeks from now. I purchased some replacement parts for the Mazda truck chassis from the wreckers; namely a complete front brake set-up (the original front brakes were very rusted and needed rebuilding) and a spare wheel stud and nut to replace a broken/ missing one. The second hand front brake set up was $500, which I think was probably still cheaper than me trying to rebuild cylinders/re-manufacture all the steel lines... not to mention that I probably needed to replace at least double that in new parts. I hope to fit these up in a couple of weeks.Below is a photo of one of the hubs/sprockets. Comments and questions are welcome!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-5908374597684140645.jpg)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on August 30, 2015, 10:32:18 AM
I am always amazed what this laser technology is capable to do.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on September 12, 2015, 09:59:26 PM
updates below
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on October 23, 2015, 09:56:28 PM
Worked on the machine a little yesterday. Finished fabricating the additional support for the front of the conveyor where the sprocket shaft mounts. I chose to use a 3 bearing support here, I think the forces on the shaft would have been excessive if only 2 bearing were used. This set-up makes the shaft more difficult to align however using mostly materials I've had on hand I only had to purchase 1 P208 bearing housing and a 1.5" bearing to go with it, the other parts being salvaged from scrapped machines. I built everything in-situ using squares and measured everything numerous times and it all seems to align correctly. If alignment ever becomes an issue I can remove the centre bearing housing and run the shaft as is, albeit overloaded.

I welded the hubs into the sprockets and then cut the second-hand shafting I have to the correct lengths. I piece already had a key-way milled into it so I cut the driven shaft to length so as the key-way was in the correct position. The longer drive shaft has one key-way in the correct position, however I'll have to get another milled this week some time. Hoping to have all the convey components together sometime next week.

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-7490538254963307743.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--4749462002871895647.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--4467910762644907448.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--8311070454076272631.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-3064628028210598594.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-%3Cbr%20/%3E62766231131555063.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--634955773869329041.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-6529191439463899804.jpg)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on October 25, 2015, 05:26:10 PM
Looking good  8)
Your are a patient man !
Just thinking of all my projects who would made live easier if they're ever get accomplished, while I am still doing things the hard way.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on December 03, 2015, 09:48:28 PM
Assembled the conveyor shaft yesterday. Working on the conveyor motor mount at the moment. I did get the machine on it's wheels and give it a quick clean...  also allowed me to clean the shed floor of all the grinding grit and dust. I expect to have a full day welding up the entire frame next week. then I'll start work on the log clamping arm.  Hope to have more pictures up soon.

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--8879984497577838486.jpg)


(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-1296347980215896777.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat--3173502807574172060.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-6122361200241721711.jpg)

Title: Re: Processor Build, Home Made Firewood Processor
Post by: TeaW on December 04, 2015, 10:09:55 AM
Looking good, thanks for the update.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: archertwo on December 04, 2015, 03:58:35 PM
Finally a rolling chassis. :D
I don't know if you've already said or not but will you be adding a log deck to the processor?
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on December 05, 2015, 01:25:11 AM
Thanks! Yes I will be adding a log deck, I've just drawn all the log deck parts up in and will send the files off to be cut shortly. The deck is very similar to most other processors using roller chain as the feeding mechanism. Out of interest what size motors do other people use on their log decks?
Title: Re: Processor Build, Home Made Firewood Processor
Post by: archertwo on December 05, 2015, 02:25:22 PM
I used a 23.3 cu. in. Geroler motor from Princess Auto.
I wanted the slowest (154 RPM) motor I could get that would do the job.
https://www.youtube.com/watch?v=OxLwTiRxf3c (https://www.youtube.com/watch?v=OxLwTiRxf3c)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: johndeerkiwi on December 26, 2015, 10:01:17 PM
@ Higgo,
             I hope your'e having a good Christmas beak, and it's great to see your progress on your processor.
I see some time ago you were asking about valves for activating your chainsaw motor. You are probably already on to this, but the important thing is to make provision for you motor to over-run. That is, when you stop the oil supply to the motor suddenly, you need to provide for  the motor to quickly wind down to a stop rather than suddenly "hit a brick wall". The inertia in a motor forced to stop instantly can (will) create a spike that can destroy your motor or blow hoses or valves.

As a chainsaw motor only rotates in one direction, the most common way to achieve this is to simply use standard valves to work the motor, but additionally, connect the motor's inlet hose up to it's outlet hose with a short pipe between the two, with a one way valve in the line. When running the motor, this one way valve will be held closed, but when the oil supply is shut off suddenly, the valve will be forced open by the oil exiting the motor. This will allow the oil to continue to flow momentarily through the motor, and around in a circle while the motor spins down to a stop.
A standard one way valve is likely all that you will need, they typically open at about 5 to 10 psi. But if you find the motor runs on for too long you can fit a one way valve with a slightly higher opening pressure, say 25 psi, which will put more resistance on the over-running motor and stop it quicker)

The only other common way of doing this is to use motor spool valves that effectively do the same thing (They go from oil under pressure to "float" when in the "off" position).
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on March 14, 2016, 10:53:35 PM
Sorry about the lack of updates. Work and study commitments really caught up with me the last couple of months! On the bright side, I have completed every other project I had sitting in the workshop and now have some time to spend on the processor again!

I picked up some laser cutting a while back for the log deck 'arms'... namely the pivoting points with integrated bearing adjusters. I've got the bearings and housings already and had some small shafts machined to allow each 'arm' of log deck to be driven by a single hydraulic motor. (3 arms, one motor) Each 'arm' has an independent leg that supports it when it's folded down, so in theory, a small amount of unlevel ground shouldn't matter. Yesterday I managed a couple of hours welding and got the pivots and adjusters welded on either end of each log deck arm.

The arms mount to the side of the conveyor that runs the length of the truck chassis (see the photo of it a few posts back) and fold up when not in use. I'll probably make the arms fold up using a 12V winch. I'll try and put some photos of the arms up when they are fitted to the side of the machine... should make it a little easier to understand. johndeerekiwi, I'm using a danzco saw and their manifold effectively compensates for all you have described. It can use either a cylinder or motor spool valve. For anyone else that's interested check out there website... some very interesting reading!

I should add, the pivot pins are 1.5" and the bearing housings are F208 with 1.5" bearings to hold the driven shafts. I kept the pivot pins and the driven shafts as separate items to save on bearings and housings instead of incorporating them, if it were a smaller number or smaller size I would have made the one part do both functions, which would make for a nicer (although more expensive) design. Sometimes cost wins out!

Comments and questions are welcome!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-2184841457600035293.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-877392997682719796.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-3728556213661961085.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-16353290271707075.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-171956364672326450.jpg)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on March 15, 2016, 06:53:10 PM
You're sure putting a lot of thoughts in this build.   smiley_thumbsup smiley_thumbsup .... and good looking welding beats too.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on March 20, 2016, 05:29:13 AM
Made a start on the top log roller this weekend. Took me 2 hours to get the old shaft out of the ancient steel roller... but it eventually came loose (with lots of heat and pounding from the sledge hammer!). Intending to use the roller on the top of log being cut instead of a clamp. In theory it should save some time because the roller will be driven and thus can keep the log constantly clamped while it is fed forward instead of having to be raised and lowered. After watching many processor videos this seems to the simplest way to gain a few seconds on each cut.

I had the brackets laser cut and the other parts I fabricated using merchant bar and holesaws. I bushed the arms using some 1.5" water pipe, welded the busing in, then drilled the bushing to 1.5" using a large 1.5" reduced shank drill bit. It definitely worked better than I expected it to! The arms will be hydraulically raised/lowed when changing to a new log.

I've attached a few photos that hopefully explain it a little more clearly.

Comments and questions are welcome!

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-8947466742572305120.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-2367912029786380963.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-7394882461760095761.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-4599010941738356879.jpg)

(https://forestryforum.com/gallery/albums/userpics/36796/Snapchat-8567178411806344624.jpg)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on March 20, 2016, 09:06:14 AM
Weld some chain sprockets on that top roller to get a better bite.



 (https://forestryforum.com/gallery/albums/userpics/15457/IMG_0959~0.JPG)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on March 21, 2016, 10:20:59 PM
Good idea Lopet. I'll get some 12x12 square stock and weld it around the roller to give it some 'tread'!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: North River Energy on March 22, 2016, 07:30:43 AM
If you're adding some tooth to the roll, consider shaping it some to center the logs as they feed.
Keep up the good work.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on November 17, 2016, 09:13:22 PM
Sorry for the lack of updates lately, progress has somewhat stalled due to time constraints! I seem to always have a lot of engineering work and little spare time and resources to spend on the project. Anyway, about to make a start on some hydraulic work in the coming weeks... spare time permitting!
Title: Re: Processor Build, Home Made Firewood Processor
Post by: gaproperty on December 18, 2016, 08:15:52 PM
Man there is some awesome builds.  I have a welder and if I get time I will try to build one myself. Until then I am doing things manually but use my kubota for hauling and moving wood.  Darn snow has put a damper on my operations these days but still at it.  You can look at my operations at http://www.youtube.com/c/LostCaper

Title: Re: Processor Build, Home Made Firewood Processor
Post by: Tony01 on July 09, 2017, 05:56:03 AM
Hi guys newbie to the forum but been selling and cutting firewood for 5 years time to build a processor of my own as cant afford the $60 000 au for a basic processor in my gallery are the  pics of the motor and saw i will be using for the build set up on a trailer i am yet to build still getting all components together before the build begins  BTW i cant post my pics to this post as they are in jpg form and the post dont allow that to post
Title: Re: Processor Build, Home Made Firewood Processor
Post by: lopet on July 09, 2017, 09:41:01 PM
Welcome to the forum. 
What's your saw off ?   
Always curious  to see other home made models.
It looks like Higgo had a pretty good start but somehow lost steam. :)
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Tony01 on July 10, 2017, 06:57:27 AM
Hultdins Super Saw 550 S    its a grabble saw
Title: Re: Processor Build, Home Made Firewood Processor
Post by: Higgo on September 14, 2018, 07:41:43 AM
Hi guys,

A short update from a few months ago. @lopet (http://forestryforum.com/board/index.php?action=profile;u=5457) you're right! I did lose some steam (albeit compounded by some extremly slow suppliers of a critical part!) 

So...

I finally received a gearbox component that I ordered on at the very start of May 2017 and received.... wait for it.... in February 2018!

Basically a splitter shaft for the NP205 transfer case I'm using (splits the driveshafts for the pump and wheels)

Without going into to much other detail I also had some pretty significant "life milestones" I got out of the way! 

However, I'm hoping I'll have some time toward the end of this year to do the final works on the machine.


**Pro tip**

Despite wanting to give up and fearing loosing my money on the parts I had ordered I stuck it out and eventually received them. I ignored advice from other forums about the manufacturer because they were the only person offering the parts. In hindsight I should have listened.... none the less I now have the parts I need to complete the pump drive!

*********

A post on assembling the driveshaft splitter box is coming up!

Heres a couple of pics of the parts:


(https://forestryforum.com/gallery/albums/userpics/36796/Image0.jpg?easyrotate_cache=1536924585)


A pic of the shaft itself (boot for size comparison - yes I know it needs replacing!):


(https://forestryforum.com/gallery/albums/userpics/36796/Image0_01.jpg?easyrotate_cache=1536924805)


A post on assembling the driveshaft splitter box is coming up!

Lets hope these parts go together.... 8)


Title: Re: Processor Build, Home Made Firewood Processor
Post by: TeaW on September 15, 2018, 07:14:26 AM
Glad to see you are still at it !
Title: Re: Processor Build, Home Made Firewood Processor
Post by: mike_belben on September 15, 2018, 10:43:45 AM
Nice build.
Title: Re: Processor Build, Home Made Firewood Processor
Post by: hedgerow on September 17, 2018, 08:52:41 PM
Higgo
Good to see you back hope that transfer case works like you want it to.