What are car cuts. Sawing lumber Is it scary to cut a body on frame machines

"Constructor"

But let's start with the "constructor" - the first popular way to avoid customs payments. This is the answer of the dodgy representatives of the auto business to the actions of the Russian government, which raises duties.

The scheme for importing a car under documents appeared several years ago and soon became widespread. The idea is simple, like everything ingenious: why pay the full cost of customs clearance of the car, if you can arrange for the replacement of units - the body and the engine. The rest (except for the frame) is not numbered, which means that it does not need registration. Thus, a citizen who had already once paid his native state for the import of a foreign car, got the opportunity to get off with little blood when changing the car to a more recent one of the same model: pay the duty for the import of spare parts, pay a little money for registration. The result was a fresh car with PTS from the previous one and the replacement of units included in the passport. And the old car, which ceased to be legally a vehicle, became a collection of spare parts. "Constructors" were supplied and enjoyed success. Because that was the only way to import a car older than seven years (without the crazy full duty adopted in September 2002).

Everyone rejoiced: both citizens who bought old, well-proven cars for affordable money, and sellers who received earnings.

But all good things come to an end quickly. A year ago, the government of the Russian Federation came up with the idea to close this shop by raising the import duty on the body for cars. Since November 14, 2008, the rate of import customs duty on bodies has become equal to 15 percent of the customs value, but not less than 5,000 euros per 1 piece! Therefore, the "constructor", having risen in price by 5000 euros each, lost its main trump card - an affordable price.

Cut - how is it?

In whose head and when the idea to cut cars arose is unknown. When the Japanese learned about this technology, they were shocked. Yes, everyone is shocked when they find out!

"Sawing" began to appear in the spring of 2009. A causal relationship with the resolution on import duties of January 11, 2009 is visible, in which duties on cars increased significantly and actually made it inexpedient to import cars older than 5 years, with an engine capacity larger than that of a small car.

And, as they say, the hucksters thought of it. In Japan, the back of the car is sawn off at the factory seams along the rear pillars and the threshold. It turns out two parts, they are not legally and physically a car - these are spare parts.

Jeeps are lucky in this regard: they are sawn "slightly", usually only the back, but there is also the option of sawing off the "muzzle"; while the supporting frame remains intact, because for its import you do not need to pay those ill-fated five euros. After import, the car gets to the repairmen, welded, puttied, painted and acquires its original appearance. In terms of its qualities, it is similar to a car after an accident, but not the whole. Most citizens are not embarrassed by this - after all, the frame is untouched.

But models with a load-bearing body - both SUVs and cars get there - after restoration in garage conditions, they become a machine only externally. The car cannot acquire its properties: the rigidity and strength of the body, which were laid down by the manufacturer, are violated. When it gets into an accident or after a set of high speeds, it falls apart - handicraft welds burst. Those who were sitting in the car die.

Price and legality

But the unreliability of the car is one side of the coin. There is also a second one. There is an order of the Ministry of Internal Affairs, according to which, when replacing units, a copy of the customs declaration for the body must be presented (since this is a numbered unit). When cutting, there will be no such document, which does not allow this machine to be registered legally.

It is possible to issue a "sawing" only by welding a panel carrying the body number from the old car during assembly into a freshly brought body or by forging a gas turbine engine on the body. This is fraud and fraud. Meanwhile, in Vladivostok, there are firms that openly offer to bring "sawing" and ask the client: is there an old "hardware" (apparently, so that there is where to get the body number)? To questions about the quality of such a "home" assembly, the sellers answer: "The cut is made at the factory seams. After normal welding, the car will not lose its characteristics, nothing will fall off or burst. We can bring the sawn car, clear customs and give it to you as it is, without assembly .If you have doubts about the quality of our welding, you can assemble the machine yourself."

Well, thanks - not every house has at least a soldering iron!

The cost of "sawing" without import duties is more attractive than the price of the car after all payments.

I will give a method for calculating the cost, which is used by the firm-seller. "In order to determine how much a "designer-sawing" will cost, you need to determine the average cost of such a car at auctions. Next, we add expenses to the cost of a car:

85,000 yen The cost of services in Japan, including the auction fee, transportation of a car to the port of departure from the auction, registration of export documents.

650 USD Cutting frame jeep, minivan, bus in Toyama. If a car is cut, then 600 dollars.

600 dollars Sea freight from Toyama to Vladivostok.

500 to 1,500 USD Customs duty, it depends on the weight of the car. For example, the weight of the Toyota Land Cruiser and Suzuki Escudo is completely different: the duty on the Escudo is $700, on the Cruiser it is $1300.

RUB 26,000 Customs temporary storage warehouse and services of a customs broker for customs clearance.

$1,000 Car collection, including removal by truck crane from the port, welding-painting-installation of units, filling liquids.

How to calculate "sawing"

However, it is not easy to calculate the sawn machine. The head of the technical supervision department, Nikolai Barkhutov, explained that if the vehicle came for registration with the traffic police with a title already issued to the owner, and the body and engine numbers matched those indicated in the passport, then there is no reason to refuse registration. So far, thank God, in Buryatia there have been no cases of accidents involving saw-cutting cars, as in other regions.

But in the Ulan-Ude car market there are "cuts", and quite a few. This is reluctant and only secretly confess sellers. I was shown a couple of Toyotas confidentially. Outwardly normal cars, without visible traces of body repair, with a large engine: it is unprofitable to cut and cook a small car.

The cutting machine must be impregnable. And the seller will say that this is an ordinary "constructor". The places of cutting and welding will come out only in case of an accident, when it will be too late. Crawl through the skin to see the place of the proposed weld, not a single seller will allow. Therefore, it is advised to look at the TCP and by the body numbers through the auction "punch" when the car was bought in Japan. If after the new year the car is also declared as a "designer" - this is a "sawing".

A familiar bodybuilder advised me to look at the places where the body was cut; for SUVs and SUVs, these are the luggage compartment windows. You can see traces of welding there. Armed with this information, I went along Prirechka and found a couple of suspicious cars myself.

Familiar distillers advised to pay attention to Harrier and LC Prado.

My friends asked me not to say the word "sawing" even in a whisper - otherwise they would "roll into asphalt."

Having gone through all the Toyota jeeps and SUVs that do not have local mileage, I finally found two Harriers with clumsy seals on the "windows". Both without mileage, with maximum three-liter engines and over 5 years old. Both cost together more than a million - with this money you can "roll asphalt" very thickly! I could not even believe that here it is, this horror!

I stared silently and went on, thinking about my own. For example, the fact that the public that buys expensive cars treats them without trepidation is not the first and not the last car. "Japanese" have long won the reputation of being reliable, and it is unlikely that a reputable buyer will climb the body, examining every centimeter personally, as poor motorists do. And in vain, as it turns out!

P.S.*If this material prevents at least one accident and saves someone's life, I will be happy. And don't give thanks.

*No one would invent these dangerous schemes if the state did not remove the opportunity to import a used foreign car into the country at normal duties. Here is a dialogue from one Internet forum (style saved):

“I came up with the idea: when bread is baked, there are also crumbs left to the dick. Take them for a penny, glue them into bread molds and sell them.

"That's when bread rises in price and becomes a luxury, then craftsmen will appear who will glue the crumbs. God forbid we live to see such times!"

Sawing lumber- the fundamental process in wood processing. First, we need to recall a few terms that are used in the woodworking industry and which are defined by GOST 18288-87 sawmill production terms and definitions:

Lumber. Materials that have one or more even sides. Depending on the ratio of length to width and the number of parallel sides, timber, bars, boards, obapol and sleepers are distinguished.

• bars- thickness less than 100 mm, width does not exceed twice the thickness. This category also includes slats, only their linear dimensions are much smaller.
• bar- thickness more than 100 mm, width does not exceed double the thickness.
• Boards- width exceeds two thicknesses, can be cut (all four sides are cut) or unedged (sides are not cut).
• Sleepers- this is a beam with strictly defined dimensions, used during the construction of railways, is currently rarely used.
• Lagging- the more familiar name "croaker", the outer side of the whip, has only one flat surface. Most often used for further processing into wood chips.

sawing wood methods

This is a very important factor; the overall yield of lumber and their quality largely depend on the chosen method. Depending on the direction of the cut to the annual rings, there are two ways:

• Radial. The highest quality lumber has an excellent structure and high rates of physical strength. The saw moves perpendicular to the annual rings.
• Tangential. It gives a much higher yield of lumber, but their quality is somewhat lower. The saw moves parallel to the annual rings or in a tangential direction.

The choice of a particular sawing method depends on the end use of the lumber and the condition of the whip. On the Internet you can find "strange articles" about sawing in a circle and so on. In fact, the vast majority of the whips are in the same position during sawing, as a result, part of the lumber has a tangential cut (about 2/3 of the total), and the rest of the lumber has a radial cut. The top and bottom of the log are cut tangentially, only the middle is sawn radially.

At the request of the customer or taking into account our own production, the whip can be sawn from the sides, then turned over by 90 °, sawing is performed again. As a result, a part of the unedged boards with a tangential cut is obtained, and the rest of the boards will be edged with a radial cut. Once again, we repeat that the cutting methods are selected in each case separately, taking into account the above factors. Currently, there are three types of sawmills, each with its own advantages and disadvantages. Let's talk about them in more detail.

Frame sawmills

These are the first mechanisms that began to be used for mechanical sawing of wood. Today, in our opinion, undeservedly "out of fashion." Consider objectively their advantages and disadvantages.

To make it clearer, you need to learn about the principles of work. On a frame sawmill, several saws are fixed in a vertical position (from ten or more, it all depends on the size of the frame), the distance between the saws is set once, sawing is carried out by the vertical movement of all saws with simultaneous feed of the whip.

pros.

• You can fully mechanize the whole process
• The sawmill is easy to set up and maintain
• Performance is at an acceptable level
• Saws the entire whip in one pass
• All received unedged boards can be cut at the same time and also in one pass
• Edged board is of high quality
• Time saving

Minuses

• It is believed that these sawmills convert a large amount of wood into sawdust. But this is true only for older models. Previously, saws were made from not very high quality steels, the thickness of each saw was up to 3 mm, plus a set of teeth, the cut increased to 5 mm. Today, by reducing the thickness of the saw and the angle of the teeth, the thickness of the cut is significantly reduced. We will compare the thickness of the cut with a band sawmill below, you will find out what their manufacturers are silent about.

Band sawmills

They are considered the most advanced equipment, the most productive, the amount of sawdust is minimal. We will discuss this later, but first we will briefly describe their structure and principle of operation. The cut is made by closed high-speed saws, the thickness of the saws is small, the width of the cut is reduced. Sawing occurs due to the forward / return movement of one saw along the whip. To be honest, we do not notice any special advantages (for the buyer), but there are disadvantages. In order not to be unfounded, we will talk about the intricacies of the cutting process.

Sawmills require a very attentive attitude. Incorrect sharpening of teeth, incorrect tension or choice of cutting speed (all of these parameters are chosen taking into account the type of wood) cause the lumber to get a wavy surface. The height of the waves can reach several centimeters. And such a waviness of even one board negates all the “advantages of a thin cut”. The wave on lumber is a visible defect in processing and reduces the grade of lumber. The classification of wood defects is described in detail in the article of the same name.

These sawmills have a rather low productivity, requiring a lot of physical labor. For example, if your whip has a diameter of 100 cm, then calculate how many back and forth passes you need to make to cut it into boards 2 cm thick, and the frame sawmill will cut it in one pass. In addition, each sawn board must be manually removed from the sawmill and stored in a separate place. In this case, after each cut, you have to set the level of the saw again. Very high degree of danger during operation. The risks of injury while working on such a sawmill increase exponentially - this is a break in the saw at high speeds, and the presence of metal objects in the body of the tree (and this does not happen so rarely). Problems with cleaning sawdust. They are scattered along the entire length of the sawmill, it is long and difficult to remove them.

Of course, manufacturers of band sawmills are “shamefully” silent about such “subtleties”. When choosing a sawmill, we advise you to take into account the maximum number of factors: the required volume of lumber, the availability of qualified personnel, the features of lumber and the requirements for their quality. After all, professional workers at the band sawmill produce lumber of the 1st grade in accordance with GOST.

pros.

• Relatively inexpensive
• Sawing in both horizontal and vertical direction
• Large whip thickness, up to 400 mm
• Low waste
• Purity saw

Minuses

• Poor performance
• Increased degree of danger
• Complex setup
• Highly qualified personnel
• Mandatory "rest time" from 8 to 10 hours
• Cleaning

Circular sawmills

Circular saws differ from band and frame (multi-saw) sawmills in the quality of the edges and the parallelism of the face. Lumber produced at a sawmill is rightfully considered the best, but only from the point of view of the consumer. The main factor that makes lumber produced at the sawmill unavailable for consumption is the high price. The high price does not allow to compete in the building materials market, despite the excellent quality of boards and beams produced by this method. This circumstance is connected with three facts affecting the increase in the cost of lumber from a sawmill:

Summarize: when choosing edged lumber, it is necessary to take into account not only the method of sawing lumber, but also the qualifications of the personnel servicing this equipment. You can buy good quality lumber from a trusted supplier, having familiarized yourself with the products according to the proposed photos on the manufacturer's website or arriving at the finished product warehouse. The Elka-Palka company is ready to offer its services in accordance with the price lists indicated on our website. We sell only high-quality products of our own production or purchased from trusted suppliers. Mandatory quality control.

22.05.2015

Purpose and types of frame saws

Frame saws - the cutting tool of sawmill one-two-story and container vertical sawmill frames. They are designed for longitudinal sawing of logs into beams, bars, boards and a container plank. Tool factories currently produce two types of saws: for vertical sawmills according to GOST 5524-62 and for container sawmills according to GOST 10482-63.
Frame saws according to GOST 5524-62 are made in two types (Fig. 29, a): type A (I) and type B (II). Type A saws have riveted bars at the ends, but B saws do not. Gang saws of type A are fixed in saw frames with removable grips and are used in saw frames with continuous feed. In these frames, depending on the amount of log feed, a change in the slope of the saws is required, and the design of frame saws with slats allows the necessary change. Type B saws are mounted in the saw frame with riveted grips and are mainly used in sawmill frames with a log inching feed per working stroke, in which a change in slope is not required. Te and other saws can be operated with set flattened teeth.

Saws for container sawmill frames are produced without straps according to the drawing in fig. 29, a. They differ from the sections considered at the ends of the blade, which are free from teeth (40-60 and 70 mm, respectively) and the dimensions of the blade itself. Such saws are also installed in the saw frame with the help of riveted grips.
The productivity, cut quality and durability of frame saws depend mainly on their design and preparation for work.

Gang saw design

The frame saw has two main elements; canvas and a gear rim notched on one of its edges.
The saw blade is characterized by its dimensions: length L, width B and thickness s (Fig. 29, a). The length of the gang saws depends on the stroke height of the saw frame and the maximum diameter of the sawn log and can be determined from the following relationship:

To increase the rigidity of the blade in the transverse direction, saws with the shortest possible length should be used. Saw blades for vertical sawmill frames are available in three widths: 160, 180, 200 mm, and for tare frames - 80 mm. As the teeth are sharpened, the width of the blade decreases. The minimum blade width that provides sufficient strength and rigidity for saw blades in operation is approximately 75 mm. The thickness of gang saws is determined by a number of conflicting requirements. To increase the rigidity (stability) of the saw during the cutting process, it is necessary to increase the thickness. An increase in thickness leads to an increase in the consumption of wood into sawdust and cutting power. The thickness of the frame saws is approximately determined by the empirical formula:

A smaller value of the coefficient (0.1) is taken when sawing softwood with flattened saws, a larger value (0.12) - when sawing hardwood and frozen wood. When sawing logs of significant diameters, the middle saws in the set are set 0.2-0.3 mm thicker than the outer ones. The dimensions of frame saws manufactured by domestic tool factories are given in Table. 14.


Gear ring design frame saw is shown in fig. 29, b. GOST provides for the production of all types of frame saws with a tooth profile having a broken back edge.
The following values ​​of the linear and geometrical parameters of the tooth have been established by the practice of work. Tooth pitch (according to TsNIVMOD)

For a flattened tooth, an increase in pitch is allowed due to the better quality of the sawn surfaces. The choice of tooth pitch should be made depending on the working conditions and the thickness of the saw (see Table 5).
The height of the tooth is set from empirical dependencies:

The higher the tooth, the lower its rigidity, but the greater the volume of the chip cavity. Therefore, when the cavity is not stressed, a smaller tooth height should be taken. To improve the conditions for the movement of chips in the cavity, its bottom is formed along the radius r, the value of which is determined by the following empirical dependence:

The volume of the cavity is better used with a smaller pitch of the teeth, but their higher height. A larger radius of curvature reduces the resistance to chip placement in the cavity. The dimensions of the teeth of the frame saws are given in Table. 15.
Saws according to GOST have a symbol. For example, when applying for saws for vertical sawmills of type A, 1600 mm long, 180 mm wide, 2.2 mm thick, with a tooth pitch of 26 mm, they are designated: PR-A 1600x180x2.2x26, GOST 5524-62.

For container saws, in the symbol, instead of PR, PTR is put and the type and width of the saw are not indicated.

Technical requirements for accuracy and quality of gang saws

Frame saws are made of steel grades 9HF in accordance with GOST 5950-63 or cold-rolled band of steel 65HF. The hardness of saws along the entire length should be within HRC 42-46, and for container saws with a pitch of 15 mm HRC 45-50. Limit deviations of frame saws from the established dimensions should not exceed the values ​​\u200b\u200bspecified in Table. 16.

Design options for frame saws

In sawmilling, frame saws of several design options are used.
Cross cut saws(Fig. 29, b) can cut off groups of fibers (whiskers) formed on the lower face of the sawn timber and connected to it by one of the ends. The pitch of the undercut teeth is 16 mm, they are cut in such a way that in the upper dead position the lower undercut tooth enters the cut by 10-12 mm, the divorce is 0.1-0.2 mm more than that adopted for the cutting teeth of the saw.
Planer saws(Fig. 29, d) are used for simultaneous planing of sawn products with high humidity with low requirements for surface cleanliness (bridge building and shipbuilding beams). The disadvantage of such saws is a relatively short service life due to the presence of slots for planing cutters.
Saws with teeth equipped with tungsten carbide blades, the most efficient type of cutting tool. However, the creation of reliable workable saws of this kind requires extensive production experimentation.

Preparing frame saws for work

Preparation includes attaching planks or grips to the ends of the saw, straightening and rolling.
Fastening bars and grips to the ends of the saw. To install saws of type A in the saw frame, it is necessary to rivet two strips to the upper and lower ends of the saw. The bottom end of the straps are riveted at the factory. A set of strips and rivets for the upper end is sent by the factory together with the saw, and their fastening is carried out at the place of operation. Before riveting the strips, the saw is cut in length if it does not match the length of the saw frame, and in width if there are broken teeth, cracks or a discrepancy between the tooth pitch and sawing conditions. Trimming is carried out at a right angle to the trailing edge on the PSh-3M, PShP-2 sawmills or scissors. Marking is done using a ruler and a square or a template ruler, the length of which is equal to the distance between the saw blades. Holes for rivets are punched with a beard and a hammer or on a saw die with a round punch along the markings or the jig. Hole diameters should be 0.5 mm larger than the rivet diameter, and the accuracy of the distances between the hole axes is ±0.1 mm. After riveting the strips on one rivet, checking the supporting surface of the strips along the square and matching the holes in them with the holes in the saw, a second rivet is placed, etc. The heads of the rivets are ground flush with the surface of the strips. Similarly, grippers for type B saws and tare saws are riveted.
Editing of saw blades. In the process of manufacturing and operation, due to uneven tension, strong heating, transverse bends of the frame saw blades, local defects are obtained: bulges, tight spots, weak spots and transverse bends (Fig. 30, a). These defects disrupt the normal operation of the saw, therefore, before rolling, they are corrected manually on the anvil with special saw hammers (Fig. 30, b). To detect defects, the saw is bent in a special device with a radius of curvature of about 2 m, and both of its surfaces are examined in turn with a short test ruler (see Fig. 27, i). When determining the exact boundaries of defects, the ruler should be rotated at different angles to the longitudinal axis of the saw. The boundaries of defects are outlined with chalk.
Bulge B (see Fig. 30. a) is found in the form of a bulge on the inside of the curved saw and a depression in the same place on the other side. The bulges are removed with a saw hammer with a round head. The first light blows are applied around the bulge, then along its edges. Finish editing with stronger blows to the center of the bulge. In order to avoid stretching of the metal between the sheet and the anvil, several thick sheets of paper are laid or editing is performed at the end of the hard rock churak. Bulges of an elongated shape are straightened with a hammer with an elongated striker. Blows are applied from the edges of the bulge along the length to its middle. After correcting on one side, the saw is turned over and ruled in the same way on the other side.

Tight place T is found as a bulge (hump) on the inside of the curved saw in any of its positions. The tight place is eliminated by double-sided forging or rolling with elongation (stretching) of the metal. When forging, the saw is placed on the anvil with its hump up.
Weak spot C is found in the form of a concavity (light gap) on the inside of the curved saw in any of its positions. The metal in the slack area is excessively elongated and, as it were, surrounded along the contour by the rigid parts of the canvas. In a horizontal position, the slack appears as a bulge. Weaknesses are corrected by double-sided forging or rolling near their edges to stretch the metal near the weak point.
Bending And is found in the form of a curvature of the canvas, most often at its ends. To eliminate this defect, the saw is placed on a test plate and a twisting ridge is found, which looks like a bulge. Then the ridges are forged along the axis on both sides with a hammer with a longitudinal striker. The straightened saw should be flat along its entire length and, when applied to the test plate, fit snugly against it with its entire surface.
Rolling of frame saws. The necessary stability, rigidity of the frame saw blade, characterized by the amount of deflection in the lateral direction from the action of the transverse force, is achieved by tensioning the saw in the longitudinal direction. The magnitude of the total tension force is limited by the strength of the saw frame and grips. Usually, the stresses of the edges of the web are increased by weakening its middle part. To do this, the saw is subjected to special processing - rolling. The middle part of the saw blade is rolled between rotating rollers under pressure, as a result of which it is somewhat elongated compared to the edges and receives compressive stresses. If now such a blade is stretched in a saw frame, the side edges of the saw will receive greater stresses and greater rigidity than with an untreated blade with the same tension force. The rigidity of the treated fabric (according to Prof. A.E. Grube) increases by 10-20% compared to the untreated one. Frame saw blades are rolled on special rolling machines PV2, PV5. The hydrokinematic diagram of the PV5 rolling machine is shown in fig. 31, a. Both rollers (3 and 4) of the machine are driven, there is a hydraulic clamp, the pressure between the rollers is set according to the pressure gauge. Rolling speed 10 m/min, machine productivity 150 saws per shift.

The middle part of the saw is subjected to rolling at a distance of 20-25 mm from the trailing edge and the line of tooth cavities (Fig. 31.6). First, the middle band of the saw is rolled, and then symmetrically adjacent sections with a gradual decrease in pressure. The edges of the saw and its ends with a length of 120-150 mm are not rolled. The degree of rolling of the saw is determined by the value of the light gap of its transverse curvature during longitudinal bending with a radius of curvature of 2 m. The transverse deflection is changed with a short test ruler and probes or a test ruler with an indicator (Fig. 31, c). The pressure of the rollers and the recommended degree of rolling, depending on the thickness of the saw, are given in Table. 17 (according to V.F. Fokin).
As the saw wears out, it is rerolled. During the service life, the number of repeated rolling of the saw does not exceed three or four.

Installing, fixing and aligning the saws in the saw frame

The correct position and fastening of the saws in the saw frame is one of the main conditions for the productive work of the saw frame.
Fastening saws in the longitudinal direction. It is carried out by captures of two types: deaf and removable. Blind grips are riveted to the saw blade and are used only for type B frame saws and container saws. Their disadvantages include: the impossibility of changing the slope of the saws depending on the feed rate, bulkiness, the need for riveting as the saw wears out in width, etc. For type A saws, quick-detachable hinge grips with a screw or eccentric tensioner are used. Removable grips (lower and upper) differ from deaf removable grips by the presence of cheeks, with the help of which the saw blades are fastened and tensioned in the longitudinal direction by the strips riveted to the ends of the saw.
The design of screw grips is shown in fig. 32, a. The saws are tensioned evenly and smoothly by turning the M16 screw with a wrench. The disadvantage of these grips is the slow tension of the saws and the rapid wear of the thread, as well as the impossibility of sawing boards thinner than 25 mm.
Eccentric grips are shown in fig. 32b. They are more perfect and therefore the most common. The saw blades are pretensioned by moving the sub-eccentric wedges, and the main tension is performed by turning the eccentric. The eccentric is made with an eccentricity of 5-7 mm along the Archimedean spiral. The wedge of the eccentric grip to ensure self-braking should have an angle of no more than 6-7 °. The eccentric is turned with a special key with a handle no more than 500 mm in order to avoid excessive tension of the saws. Eccentric tensioners provide fast, smooth and reliable saw tension. The dimensions of the main structural elements of the unified grippers ZU-18 and ZU-22 are determined by the strength requirements. The saws should be pulled gradually, in two or three steps, and symmetrically, starting from the extreme saws and ending with the middle ones. The normal rigidity of the saw is ensured in the presence of stresses in its cross section of the order of 8-12 kgf / mm2.

The tension force of one frame saw for two-story sawmill frames can be determined from Table. 18 (according to the norms D98-10 of the Severny Kommunar plant).
In the process of work, the saws, heating up, lengthen, as a result of which the normal stresses decrease and this can lead to poor sawing. The normal heating temperature of the saws is on average 40-50 ° C; the rear edge of the saw heats up by 15-20 ° C higher than the cutting edge. Therefore, after sawing the first two or three logs, it is necessary to additionally tighten the saws. The tension of the saw when it is cooled reaches an average of 14-16 kgf / mm2, which leads to significant deformations of the saw frame and even its breakage. During long breaks in work, the tension of the saws should be loosened.

The listed designs of tension devices have a number of common disadvantages. There is no tension control, and individual saw blades have different tension forces; there is no compensation for elongation of the saws when they are heated; a change in the tension of one saw set leads to a weakening or an increase in the stress state of the others. To eliminate these shortcomings, domestic enterprises use hydraulic tensioners (Fig. 32, c), which make it possible to ensure the same tension of all saws and automatically tighten them when heated. Hydraulic tensioners of the following brands are produced: PG-30 - for a set with a width of 300 m, PG-40 - for a set with a width of 400 mm and PG-56 - for a set with a width of 560 mm. The weight of hydraulic tensioners is 13-22 kg, the tension force is 3000-4500 kgf.
The hydraulic tensioner is a closed non-motorized hydraulic system consisting of three units: a pressure generator, a hydro generator housing, in which vertically arranged pistons serve to support the upper grippers of frame saws, and a support wall. The device is mounted on the upper traverse of the saw frame and attached to it with hooks.
The use of a hydraulic tensioner increases the productivity of sawmill frames by 3-4% due to the elimination of downtime caused by pulling up the saws during sawing, improves the quality of sawing, facilitates the work of the framer and sawmill.
Fastening saws in the transverse direction. It is carried out with the help of special gaskets (separation) and clamps. To do this, the gaskets are inserted between the saws at the top and bottom and compressed with clamps mounted on the racks of the saw frame. Setting the center of the setting in the center of the saw frame is carried out by selecting the side paired spacers placed between the clamps and the edge saws of the setting. To determine the size of the side gaskets, use the template box for the set of set.
Gaskets perform several functions: with their help, saws are fixed in the transverse direction; they reduce the free length of the saws, which becomes equal to the distance between the upper and lower spacers, thereby increasing their rigidity; provide the required distance between the saws. Gaskets are wooden, metal and combined. The most widespread are wooden gaskets (Fig. 32, d). They are light, simple, cheap and cut from dry birch or larch. The disadvantage of wooden spacers is low strength. The thickness of the spacers depends on the thickness of the boards being cut, the shrinkage allowance and the widening of the saw teeth:

Clamps that tighten the set in the transverse direction are divided into clamping and expansion clamps. The most common spacer clamps with one or two pressure bolts (Fig. 32, e). Single-bolt clamps allow for faster set-up adjustments, but make it difficult to straighten the saws parallel to the rails. Clamps mounted on the left stand of the saw frame (along the log) are called root, on the right - clamping. The root clamps are fixed motionless, and the gaskets are pressed by pressing. The lower clamps are set along the height of the saw frame so that in the upper dead position there is a gap of 50-70 mm between the spacers and the line tangent to the upper points of the lower sending rollers. The top clamps are set depending on the maximum diameter of the log in such a way that in the lower position of the frame there is a gap of 80-100 mm between the top spacers and the highest point of the butt of the log.
Alignment of saws in a saw frame. Includes setting the slope, checking the parallelism of the saws to the direction of movement of the log and the line of movement of the saw frame. The slope of the saws is set using inclinometers of the Vardashko system or TsNILSevzaples. These inclinometers have levels with a scale. When checking the slope, the inclinometer is pressed tightly with the base surface to the tops of the saw teeth. If the actual slope corresponds to the required one, the level bubble will be located in the center of the scale; if the bubble deviates from the center, it is given the desired position by hammer blows on one of the ends of the saw. The slope value is set by moving apart the hinged wooden bars (on the Vardashko inclinometer) or raising the level bar with a micrometer screw (on the TsNIILSevzaples inclinometer). The slope of the saws is necessary when the log is fed over idle. It ensures the movement of the line of the tops of the teeth in a horizontal plane and eliminates the pressing of the log on the saws.
The parallelism of the saws is checked using a control ruler and a square (Fig. 32, e). To do this, the control ruler is installed on special squares of the frame of the sawmill frame and a square is applied to it. The long plate of the square, normal to the ruler, will then be located strictly parallel to the direction of movement of the log. On this plate, when moving the square along the set, all saws are installed, first in the upper position of the saw frame, then in the lower position. The vertical position of the saws is checked with the same square. In the upper position of the saw frame, the square is pressed against one of the saws and its position is fixed. Move the saw frame to the lower position. Set the square to its original position and check if its bar touches the surface of the saw. In the case of a gap, the saw blades are moved in the desired direction with the help of upper clamps.
When installing saws in a saw frame, it is necessary to pay attention to the location of the grips along their width, since it has a great influence on the distribution of stresses over the cross section of the saw. Due to the fact that the rigidity of the blade mainly depends on the stresses in the cutting edge, the saw should be positioned in the grips so that the axis of symmetry along the width of the grips, (tension line) is located between the cutting edge to the center line of the saw. The value of the displacement of the tension line from the axis of the saw towards the cutting edge (eccentricity) is recommended (according to Prof. A.E. Grube) 0.15, where B is the width of the saw.

ATTENTION! FROM 25.03 IT WAS POSSIBLE TO BRING CONSTRUCTION DESIGNERS WITHOUT CUTTING UNDER PTS ACCORDING TO THE OLD SCHEME.

The fee of 3,000 euros has been cancelled! The body is separated from the chassis and the engine. Nothing is sawn, only minimal parsing!

If you need a donor for spare parts, it is better to carry a cut on screeds, without assembly. It is cheaper than the designer by about 30,000 rubles.

What is a "constructor"?

The car is dismantled to save on customs payments. The car is disassembled into the body of the 1st configuration, the engine assembly and the suspension. Nothing else is affected. Documents issued: i.e. CCD (cargo customs declaration) for a body with a number, a frame and an engine. Driving such a machine on public roads is prohibited, but it can be transported on a tow truck. Delivery by the “constructor” method is the most expensive, delivery by “karpil” and “cutting” is much cheaper. Designers now carry only trucks and pickups, there is no point in ordering cars and jeeps from Japan by "constructors". Firstly, because of the very high cost (1.5-2 times more expensive than "cut-karpilov". Secondly, because of the difficulties in registration on the title. The designer is a car for your documents, operation is impossible without the title .

What is a "cut car"?

This is a car that is bought in Japan as a whole. Then it is sawn in order to pay a duty when imported into Russia as for spare parts, and not for a whole car. Cutting is a car for your documents, operation is impossible without a TCP. The machine is sawn on the back or on the front. The roof racks are cut in the middle and the floor in the cabin, the roof is not sawn.

For minibuses, the cut is carried out “figuratively”, from the front right door to the rear left (sliding) door through the engine compartment. Frame jeeps are sawn in front or in the back in the middle of 4 roof pillars (near the windows of the “dog house” in the trunk) The frame is not sawn! The body rises from the frame, on which the engine remains (unscrews from the pillows) and the chassis.

Parts of the body are pulled together with ties, outwardly it looks like a whole car. It is even possible to move around on such a cut in a warehouse or parking lot, plus the cuts are that practically nothing is disassembled from the car. Then the car is assembled (welded) on a turnkey basis for further operation.

FIGURED CUT OF MINIBUSES:

The cut passes from the front right door through the engine compartment to the left side sliding door. Nothing is disassembled, except for the skin, only cut!

What is "karpil auto"?

This is a car that is bought in Japan as a whole. Then it is disassembled so that when imported into Russia, the duty is paid as for spare parts, and not for the whole car. Karpil is a car for your documents, operation is impossible without a TCP. Only the front panel (TV, nouskat) is sawn. This does not affect the integrity of the body of your car from Japan. And also guarantees its further safe operation. Not a single traffic police inspector will find seams on your body, because they simply do not exist.

Partial dismantling of the car is carried out, removed:
- engine with automatic

Chassis

Headlights, grille, fenders (all doors, hood remain in place!)

It is not possible to import cabover minibuses (for example, old Mitsubishi Delica), as well as left-hand drive vehicles, with the exception of those that have Japanese counterparts, to order from Japan.

Why do customers buy car saw cuts (carpiles) from Japan?

In the event that a person crashed his car and it is not recoverable. Either the car is rusty and in poor condition. Often the cost of spare parts and repairs is obviously more expensive than the price of a cut from Japan. It turns out that it is easier to order a cut and “transfer” the necessary spare parts from it to your car. The remaining parts are sold or kept as spare parts. If the body cannot be restored, then there are other options. In this case, you will end up driving a car that came from Japan, but according to your old documents.

Where do the documents come from, under which it is possible to order a cut-carpil?

These are documents from your old car, which is not subject to restoration, or sold for parts. Also, documents with a frame or with iron (bar) can be purchased on the Internet.

Why is it not profitable to buy a car from an “honest designer”, as before?

Firstly, at the moment it is very difficult and expensive to issue an “honest designer”. Previously, it was much easier, so there was a sense of such an import. Secondly, earlier designers of the 1st configuration were not subject to a high duty of 3,000 euros per body, as they are now. When importing a cut or carpil, the duty for the body of the 1st configuration is not paid.

Why is it not profitable to buy a car with the front half?

Because the cost of shipping and customs clearance of a half from Japan is not much less than for cutting. But when ordering a cut, you will also have a completely rear part of the car.

What cars are profitable to buy from Japan by sawing (karpilom)?

Basically, any. Completely different cars come into disrepair for various reasons. But we must keep in mind that even the cheapest car bought in Japan for $ 300-500 will cost 150,000 rubles without assembly in Vladivostok (it fluctuates with the dollar).

Cutting a car without assembly is much cheaper? Karpil how much more expensive than cutting?

Sawing without assembly is cheaper by 20,000 rubles. Karpil is more expensive than cutting by about $ 400.

Can I choose a car one to one (color to color, body to body) for my documents?

Yes, sure. All parameters of the car are specified in the application to the contract. Based on it, we carry out the selection and purchase.

To whom will my cut (karpil) be sent from Japan? What documents will I receive?

The cut (karpil) comes to a legal entity. The same company is a broker who will carry out customs clearance of the car. In the future, you will receive a sales contract for numbered units (engine and frame). For the rest of the spare parts, there will also be customs documents (CCD), they are enough to transport the car.

Do you have a quality cut assembly?

Yes, build quality. The seams are additionally welded and treated with an anti-corrosion agent. Duplicates are set. All work is carried out by professional Russian craftsmen with at least 5 years of experience in similar work. Whole roof racks are painted if they have been cut.

Do you have a quality assembly of carpiles?

Yes, build quality. Interior and body parts are dismantled and neatly packaged in Japan. This avoids damage to spare parts during transportation. The assembly is carried out by qualified specialists, as a result, your car is returned to the condition in which it was bought at the auction.

I heard that sometimes during delivery, various parts disappear from the designers. As a result, you have to buy them at your own expense. Is it so?

Yes, this happens occasionally. Our company is responsible for the full compliance of your car with the condition at the auction, when buying it in Japan. If during disassembly, transportation and assembly there is a loss or damage to components, we will compensate for this at our own expense.

The car, probably, after a complete analysis to the carpil and assembly, will it already be more like Russian, and not Japanese?

We assure you that after assembly by our masters, you will not be able to distinguish a car from a regular one. During everyday operation and repair, the car is periodically dismantled: for example, when installing an alarm, cleaning the interior, repairing after an accident, replacing the engine. Having proper experience in disassembling and assembling Japanese cars, the quality after the assembly of the karpil constructor does not suffer. What can you be sure of when you take the car.

Can you send a cut (karpil) of a car to the region without assembly?

Yes we can. The saw cut in this case is not going to, the front and rear parts are attached to the screeds. A cut without assembly will look like this:

For Karpil, sending without assembly is possible, but does not make any sense. Carpiler spare parts pallets are heavy and take up a lot of space. As a result, the tariff of the transport company for sending them will be similar to the cost of assembly, and may even exceed it.

Can you draw up a cut (karpil) or find documents for it?

Registration of cuts and carpils on documents is impossible. They are ordered by those who crashed their car and have a TCP and iron on their hands (a bar with a body or frame number). If you want to buy a cut (karpil) and you don’t have the same broken car, then you can search for a PTS with iron among the ads for the sale of documents. Thus, in the end, you will operate an already impassable car, but on your old numbers and documents. Another option: all components and assemblies from a cut from Japan are installed on the body of an old car.

I have a frame, can I bring it to you, and will you assemble my constructor with it?

Yes, you can. You can bring us either the frame or your entire vehicle. We will remove the old units from your frame and put new ones on it. We can also rearrange all units from your old car to a Japanese frame. As a result, you will take 2 cars from us, although one will be without documents.

How does this happen? Do I need to file a replacement with the traffic police?

Your frame is taken, then from the cut that came from Japan, the engine, body, chassis, etc. are “dressed” on it. The body of frame cars is not licensed, and the procedure for replacing the engine on the territory of the Russian Federation was canceled. Therefore, there is no need to issue replacement units in this case. As a result, you will continue to move around according to your old documents, but already in a wheelless car. Everything is absolutely legal, it will be possible to sell the car through an inspection at the traffic police.

What if my frame is in poor condition and it is not possible to install aggregates on it?

In this case, it is better to use a Japanese frame, although you will need to install the necessary fragment from the frame of your old car into it.

Is it possible to order from Japan "cutting" and "carpiling" European left-hand drive cars (Mercedes, Audi)?

Yes it is possible. Most often they are sold at auctions with a right-hand drive, but left-hand drive options are also found. We recommend ordering such machines by cuts without assembly. The car will be delivered to you in the region on screeds. It is possible to assemble a cut of such a car in Vladivostok, or delivery by carpil (without cutting), but we cannot provide a guarantee for such work. The reason is the difficulty of assembling European cars, unlike Japanese ones.

I only need the engine, transmission and chassis (or body). Can you bring it separately?

No, we do not carry a separate body, or an engine with a transmission.

On our website you can AND CUT, the prices are indicated in Vladivostok with assembly.

Contributed to a decrease in demand for transportation services from abroad. In addition, the Government supported the initiative to increase the cost of registration of "constructors", that is, cars imported for individual spare parts. Even in the latter case, the minimum costs will exceed 5,000 euros, not to mention the import of a fully assembled car. There remains one more option that is still available to the Russian consumer - it involves cutting the body into 2-3 parts and importing the vehicle under the guise of scrap metal or spare parts that are not an assembly kit. The scheme is quite simple, and there will be no problems with customs clearance, but there is one more question - how to formalize the cut in a legal way?

Option 1. Frame SUVs

As cuts from Japan, large frame SUVs are most often transported,. The reason for this lies not only in the love of domestic drivers for large cars, but also in the simplicity of design. In Japanese frame technology, there is no body number in principle - the frame number is used instead. Accordingly, the body of such a cut is divided into two parts (the front end with the engine compartment is often cut off) and separated from the frame. Customs clearance for sawing a large SUV is carried out according to two schemes - body halves can be called scrap metal or spare parts in documents - the first option is cheaper, but raises suspicions of the civil service, and the second is more expensive, but legally impeccably clean.

Making a cut will require the presence of a donor car. Previously, a scheme was used with the purchase of a ready-made TCP, but recently the traffic police has required the presentation of a base vehicle, which serves as the basis for conversion. They usually buy burnt, drowned, broken in an accident and causing damage to another type of car, since when making a cut, it makes no sense to overpay for a car that is used only formally. Experts recommend refusing to buy cars and documents, the owners of which:

• Died;
• Convicted under criminal law;
• Have debts to banks;
• Engage in illegal activities;
• Bought a car fraudulently.

Experienced motorists who know the cut are advised to hire a tow truck and go with all the donor hardware to the traffic police department. In addition to the donor for cutting, you need to present a cargo customs declaration for imported units, including the frame, body halves and motor. In some cases, law enforcement officials require you to provide sales contracts that indicate that the car was not received as a result of theft.

The owner of the cut must fill out an application for the replacement of units, the form of which is issued to him by a representative of the traffic police. If the series of the donor and sawn car completely match, the registration procedure ends here, and two weeks later the driver receives the long-awaited documents. If the car models differ, the owner of the cut is sent to NAMI, where they will need to present the finished car that has passed the welding and assembly procedure. At the maintenance point, the cut will be checked according to a special table for the replacement of units developed by the institute. Under normal circumstances, documents for the car will be issued in a week or two, although any problems that arise can stretch the registration procedure for years.

Option 2. Bearing body

If the car is devoid of a frame, making a cut will be much more difficult. The problem is not only assembly, which inevitably loses the strength of the vehicle. According to Russian customs rules, it is impossible to assemble a body from two parts without receiving a separate customs declaration and an agreement for it. Accordingly, when contacting the traffic police, the driver will simply be sent for the missing documents. It is useless to protest, because, unlike, all cars with a monocoque body have a separate plate with numbers, which is the reason for issuing a gas turbine engine.

In this case, the registration of a cut is possible in the only way - the already imported body must be welded and go through the full customs clearance procedure by paying a fee of 5,000 euros. Of course, many people are not willing to pay such a large amount of money, especially when it comes to a Japanese sedan from the 80s. Therefore, motorists are looking for alternative ways to design cuts that do not always comply with the law. We include them specifically to protect readers from liability when using dangerous methods out of ignorance:

• Registration of the body as an emergency with a reduction in duty up to 3500 euros;
• Transferring the plate from the donor to the new body;
• Buying gas turbine engines on the black market;
• Purchase or forgery of documents for the body, confirming that it was imported into Russia several years ago.

Costs and profits

When buying a frame SUV as a saw cut, the result fully justifies the costs incurred - the cost of the car will be 3–10 times lower than that of a similar one that has passed full customs clearance and 10–20 times lower than a new one. But it is not recommended to import frameless vehicles as cuts - there are few cases of legal registration of such vehicles. You should not rely on the offers of various agencies that offer, cheaply and legally - you may face criminal penalties and forcible seizure of the car.