Ortobreton 4EG - Multiblade cutting system for granite block with independent strip extractor

Ortobreton 4EG - portal block saw

Maximum rigidity to increase performances and minimise running costs 

Portal machine 

The circular blades are positioned on the machining area by shifting the block platform. 

Superframe structure

Two columns on each side of the spindle support beam provide greater rigidity.

The improved geometry minimises vibrations 

The portal block saw is the ideal solution for limiting the vibrations. Each circular blade works in ideal conditions and cutting accuracy is excellent.  

4EG block saws enhance the portal layout by means of two columns on either side of the machine. 

The portal structure enables the horizontal blade to be easily incorporated into the solid structure of the machine. The horizontal blade detaches the strips whilst the vertical ones operate.

SUPERFRAME structure     
The 4EG block saws are a real point of reference as to rigidity and stability of the cutting system.

The superframe structure provides the solidity required by a blade pack wider than one meter.

Each end of the spindle beam is rigidly fixed to two columns.

The structure acts against twisting of the spindle beam even when thrusts have a transversal component.

Vertical movement of the beam is provided by a reduction gear that transmits movement to the four angular transmissions connected to the four screws so as to ensure precise positioning.

Cutting is thus very precise, even in critical conditions, e.g. when only one side of the blade pack is working.

Unit for integrated horizontal cutting     
In the Ortobreton 4EG SFO block saws, the horizontal cutting unit is connected to the main structure of the machine but is independent from the vertical blades: this allows the unit to remove the strips while vertical blades cut the next series.                             

In this way the machine is always running, thereby ensuring greater productivity.

The horizontal blade unit slides on the two front columns and has very precise movements.  

The horizontal blade works in synchronism with the automatic vacuum unloader that moves to the right position so as to pick up and support the strip before it has been completely detached. 

The overhead structure of the unloader minimises the space occupied on the ground and enables very rapid cycles that are much less than the time required to detach the strip.

A machine designed to minimise running costs 

The running costs of a block saw are mainly due to the cost of diamond tools. The annual expense for tools may be as great as the amount invested in the machine. 

Wear of the diamond tools depends, besides on the rigidity of the machine structure, also on how the spindle carriage travels. In the 4EG model, an asynchronous motor controlled by an inverter that actuates a pair of parallel racks meshed to two pinions, moves the spindle-holding carriage. 

A dynamically balanced, large-sized spindle shaft performs the blade rotation.  In the 4EG 1100 SFO, the diameter is 210 mm and the moment of inertia is almost four times that of a shaft with diameter of 150 mm. This great moment of inertia means that the spindle shaft flexion is minimal even under heavy-duty conditions with 60 blades applied.

The unit for moving the platform into the machining area 

A rugged steel guard protects the screw in an oil bath that conveys the platform to the machining area. 

A labyrinth seal prevents water from coming into contact with the screw, which is moved by an inverter-driven motor. 

The platform reaches its working position with great precision by running on a flat and a prismatic rail. 

Management system with personal computer in Windows environment

The work of the block saw must be programmed very carefully. To increase the operator’s concentration, the machine is managed by a personal computer where a user-friendly software facilitates all operations. 

The data on block dimensions can be easily acquired by positioning the machine’s work axes using the palmtop keypad.

The personal computer can be connected to the Breton remote assistance service, which can rapidly acquire the information on machine status in order to carry out a rapid diagnosis and if necessary proceed directly with a software operation. 

Numberless statistics regarding operating time and tool duration can be processed. The programme also warns the operator when it is necessary to carry out a scheduled maintenance job.

Here you can find technical data about cutting granite block machine Ortobreton 4EG.

I'm done for today. I hope i haven't bored you.
Click here for request or other INFO.
By-by
Sergio Prior

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breton stone machinery, cutting block granite, ortobreton 4eg, portal cutting blocks granite, saw granite blocks

Breton high-duty resin-treating plant

Since 1991 SIRMERSAN Marble Industry Inc. (Cinnah Cad. 46/3, Cankaya, Ankara, Turkey) has been producing and exporting top quality marble blocks, slabs and tiles and has now become one of the largest producers of travertine with 3 quarries and 2 production sites.
In 2002, SIRMERSAN began marketing a prestigious beige marble quarried in Yesilova with the brand "White Pearl".SIRMERSAN factory is located in Denizli, the Turkish heart of marble quarrying.

A Breton automatic cutting line for marble and/or travertine slabs will start operating in September 2013. A scanner reading the slab surface and software for cut optimization (suitable even for slabs with irregular surface and inner defects) will be installed at the forepart of the line.
The line will produce tiles, strips and panels with the desired dimensions with top efficiency and precision.

A new Breton slab resin-treating plant will start producing in February 2014: it is indeed the plant with the highest production capacity ever installed in the world, capable of processing one net-reinforced slab which is resin-treated on both sides every 55 seconds.

This mega plant is fully automatic and includes six 40-level kilns, a vacuum chamber and two stations for resin mixing and spraying.

The following are its distinguishing features:
1. slabs are directly loaded from the gangsaw trolley and it is possible to handle them in the "diamond-match" pattern
2. double drying and catalysis kilns in order to ensure a cycle time of 55 seconds/slab (net-reinforced on one face and resin-treated on both faces).
3. the resin-treating and netting operations are performed automatically
4. user-friendly operational software on colour touch-screen
5. plant with a reduced encumbrance: approx. 700 m2.
Well, that’s all for today.

By-by

Sergio Prior

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breton stone machinery, cutting line marble granite, resin plant marble granite slabs

A piece produced by Breton BESTWIRE 2 AXES - single-wire machine

Hello everybody,

Today I’d like to share with you a series of photos showing a piece produced by Breton BESTWIRE 2 AXES, a single-wire machine that, besides squaring blocks and cutting slabs (even thick slabs), is suitable to shape components for funerary art such as casings, frames, columns, profiles as well as urban fittings, through the interpolation of the wire lowering vertical axis and the cart advance motion horizontal axis.
This time BESTWIRE 2 AXES produced a modern garden bench.

Indeed a beautiful work piece, almost as much as the two young ladies which tested it first!

Write to mail@breton.it for an estimate.

By-by

Sergio Prior

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Breton BESTWIRE 2AXES, breton monowire machine, squaring blocks machine

Breton at 48th MARMOMACC 2013 Verona

Good morning,

Once again, Breton will exhibit new machines for the NATURAL STONE and FABSHOP sectors at the 48th MARMOMACC in Verona.

- GOLDBRETON 2000/6/V70: machine with diamond wires for sawing blocks of granite and marble.  

Goldbreton 2000

- Breton will introduce the granite slab polisher Levibreton KG4000 PLUS at the Pavillion 5 - Stand C5.

Levibreton KG 4000 PLUS

and the 2-axes shaping machine BESTWIRE .

Bestwire

- NEW CONTOURBRETON NC300 K26, available with the following useful working travels: “X” 3.800mm, “Y” 2.300mm and “Z” 300mm. 

Contourbreton NC300 K26

- SHAPEMILL NCF 1600, a numerical control shaping, profiling, cutting and turning centre with five interpolated axes. The vertical travel of 1.600mm makes it the ideal machine for architectural and funerary art components and for the execution of deep slots.

Shapemill NCF 1600

- SMART-CUT S/NC550 OPTIMA, a numerical control cutting and shaping centre with five interpolated axes, provided with a special cutting head with integrated vacuum cups for the slab cutting optimization through the piece movement on the fixed work bench. 

Smart-Cut S/NC 550 Optima

- NEW COMBICUT DJ/NC, a CNC control cutting centre with 4 or 5 axes, equipped with a diamond disk cutting unit and a Waterjet cutting unit.

Combicut DJ/NC

- Waterjet CLASSICA, a water jet cutting machine with 5 axes.

Classica 5 axes

You will be mostly welcomed from 25 to 28 September at the 48th MARMOMACC, Pavillion 4 - Stand B6/C7 and Pavillion 5 - Stand C5.

By-by

Sergio Prior

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breton multiwire cutting granite blocks, breton polishing machine, bridge saw cnc, marmomacc 2013, natural stone machinery

Levibreton KG 3600 - polishing granite slabs

LEVIBRETON KG 3600
High speed - High performance
Levibreton KG: a project that has been a striking industrial success for both Breton, the producer, and the customers.The NEW LEVIBRETON KG 3600, combining ground-breaking concepts with well-tried solutions, is the evolution of the renowned KG 3000 that was tested for millions of hours and is used wherever in the world marble is processed.

LEVIBRETON KG 3600: a productive philosophy
Nowadays, the LEVIBRETON KG 3600 polishing lines for granite are the most valued and leading-edge answer for companies requiring high productivity combined with low conversion costs.Breton was the first to develop the continuous polishing machines for granite slabs, thus bringing a revolution in the field. Today concepts such as automation, productivity, user-friendliness, easy care and low operating costs are absolutely familiar to Breton who knew how applying them masterly to the supeior LEVIBRETON KG 3600.

Honing-polishing Units

The new design of the aluminiumalloy honing-polishing units allows their weight to be reduced and their stiffness to be increased. The spindle raising-lowering system is perfectly balanced and features two pistons with protected internal rods.  The heads are raised and lowered in fractions of a second, with minimal lifting from the surface of the slab, thus enabling the slab edges to be polished better and operating speed to be increased. The analogue manometers displaying the pressure of each single head as well as the manual pressure regulators are placed close to each spindle on the machine front, just above the sliding doors.

Beam

The arc-welded steel beam has a special design with box-type section in order to both reduce weight and provide high stiffness. The spindle/beam assembly is thus very light and dynamic, enables fast acceleration/deceleration ramps and a travel speed up to 60 m/min.

Beam drive

The beam is actuated by two Brushless-type motors at each end of the beam that are mechanically synchronized so as to ensure a high dynamic movement without stressing the mechanical components.
Motion is transmitted by means of pinion/rack mechanism, the simplest, most efficient and reliable system.
Beam working speed reaches 60 m/min. During the beam movement slowing phases, the “energy recovery” system supplies energy to the grid, thus saving energy.

Supporting structure

The supporting structure is manufactured as a distortion-proof, arc-welded steel, single-piece frame with 12 sturdy supporting legs. The conveyor belt slides upon a thick steel table, milled as a single unit to ensure perfect flatness. The conveyor belt is driven by brushless motor to guarantee better control of the feed speed.

Beam sliding supports

The beam is fixed to two shoulders moving along two sturdy, cast-iron supports, which house hardened, ground and thick tracks with large diameter roller slides in an oil bath, and a micro pinion. The slideways are protected by stainless steel labyrinth seals.

Slab profile and thickness readers
A photoelectric barrier reader stores the slab profile with 10x10 mm resolution, and a sonar reader detects its thickness. This system can accurately read even slabs with a smooth surface (such as slabs that have already been polished or resin-treated). The system allows the head lifting-lowering to be controlled automatically, ensures the self-adjustment of the beam travel to the width of the slabs and guarantees that the front, anti-splash and sound-proof protection guards are positioned automatically to match the thickness of the slabs.

The water plant
The water supply to the heads is by a common, large-diameter, PVC-made central piping, placed above the spindle units. The water supply from the main pipe to the slabs passes vertically inside the shaft of the spindle unit. With this system, when the machine is stopped, all the water inside the piping automatically flows out by gravity thus avoiding any possible stagnation and consequent build-up of solid residues inside the pipes.

Automatic control of abrasive consumption

This system performs the continuous monitoring of the abrasive consumption of each single head, with screen-messages and pre-alarm warning before the tool wears out completely. Moreover, it ensures the minimal lifting of the heads at the slab entrance/exit and their subsequent rapid descent to permit better polishing of the edges and greater operating speed.

Electric and electronic plant

The electric and electronic plant is wired with the “field-bus” technique that, by means of a single cable, transmits all the PC signals digitally to the different control units installed on the machine. Signal transmission is safe and identification of possible failures is greatly simplified. The stationary part of the machine is electrically connected to the mobile beam by a parallel sheathing system, which ensures safer working conditions and longer cable life. 
All the electric and electronic equipment, including the PC installed on the machine, is supplied by first-class international manufacturers so as to make technical assistance easier and spare parts more readily available virtually throughout the world.

The special Breton heads

The LEVIBRETON KG 3600 polishing lines can mount the state-of-the-art SG/8 Breton heads, with 8 oscillating bricks, 510 mm diameter, oil bath type or the traditional SG/6 Breton heads, with 6 oscillating bricks, 460 mm diameter, oil bath type. The SG/8 heads are based on the highly successful SG/6 head project but have been adapted for 8 bricks and offer the following advantages: 
- HIGHER OUTPUT owing to the greater number of operating sectors (152 bricks for a LEVIBRETON KG 3600 polishing machine with 19 SG/8 heads as opposed to 126 bricks for a unit with 21 6-brick heads). 
- BETTER HONING owing to the greater diameter of the heads (510 mm for the SG/8 as opposed to 460 mm for the 6-brick heads). energY-SAVING: (285kW for a LEVIBRETON KG 3600 polishing machine with 19 SG/8 heads as opposed to 315kW for a polishing machine with 21 6-brick heads).

Head lubrication


All the Breton heads operate in an oilbath system, thus minimizing the wear of mechanical parts. Each rotating head contains the required amount of oil; an additional transparent external reservoir allows the operator to know immediately and without difficulty when oil needs to be topped up and topping up is very simple.

Automatic centralized lubrication system

A centralized system, consisting of a grease reservoir, an electrically controlled pump, sequential distributors and flexible high-pressure pipes, automatically lubricates both the spindle units and other moving parts of the machine. The master distributors are equipped with overpressure indicators that allow to easily locating any possible clogging. 

Slab cleaning       

A rubber wiper fixed to the end of the machine removes water from the slab surface. A pneumatically controlled spindle, integral with the beam and equipped with a brush, cleans the slabs once they are polished. The spindle is raised and lowered automatically each time a slab goes past.

Guards, ergonomics and all parameters under control
A control board provided with analogue pressure display, manual pressure regulator and head raising/lowering selector is installed on the top part, in an ergonomic and safe position, far from water and moisture and close to each individual spindle. The head raising/lowering selector complete the board. Accident-prevention, sound-deadening sliding front panels with a sandwich-like structure. The panels are made from ABS and polyurethane, are heavyduty and resistant to water and processing wastes. Sound-deadening splash guards with a stainless steel sandwich-type structure are installed on the beam in front of the heads “at the same level as” the heads. The positioning of the splash guards is motor-driven and automatic in order to adapt to the thickness of the slab and permit opening for changing the abrasives.

Management and Programming

The colour touchscreen video and advanced userfriendly processing software enables the main processing functions to be managed, including:
• option to store (and call up) different work programmes for different types of material;
• speed of the conveyor and synchronism of the whole line, including loaders and connection roller conveyors;
• beam movement (speed, customised programming of acceleration and deceleration ramps);
• operating pressure of the single heads;
• interpolation of the operating pressure of the single heads with the actual position of the beam thanks to the metering valves;
• back-slipping correction on the anti-skid conveyor of badly-sawn, bent slabs, for both single slabs and packs of slabs;
• continuous automatic monitoring of the abrasive consumption for each single head, with screenmessages and pre-alarm warning before the tool wears out;
• option of disabling from the process all the slabs, some of them or just one slab, or even a portion of a slab (head, end, corner).

Remote diagnosis

The LEVIBRETON KG 3600 is equipped with evolved software the assisted Internet connection with Breton service, which facilitates remote trouble-shooting and expedites solutions.

Statistics
Furthermore, the PC gathers and organizes the statistical data relating to production and consumption, such as:
• production statistics on partial periods, or job orders, or working shifts, progressive or total amounts (hours during which machine is switched on, in operation, in alarm status, square meters produced…);
• tool wear statistics (per each individual head, square meters produced over a given time with the operating tool, square meters produced with the last replaced tool, etc.);
• diagnostics of machine condition, with video display of any alarms triggered;
• maintenance programming with alarm on the display when preventive maintenance has expired;
• file of the slabs processed (as they are detected by the optical reader installed at the entrance of the machine).

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levibreton kg 3600, machine polish granite, polishing granite line, polishing granite slabs