Fabricating Technology Roundup: Part I - Machinery
The following is a look at some of the latest advancements in stone fabricating machinery.
(Editor’s note: Part II of our Fabricating Technology Roundup - focusing on tooling and accessories, handling and storage, software/electronic templating, air and water treatment systems and other shop products - will appear in the February 2009 issue of Stone World.)
Sawing/CuttingThe powerful Abaco Site Saw Mod. S2 is suited for construction sites and workshops. On one side, the saw has roller conveyers, which make loading easy. On the other side, adjustable stops allow for precise parallel cuts. This saw has a cutting length of 1.8 yards (1.6 m), and it has incorporated wheels and rollers for effortless, single-handed transportation. The Mod. S2 features an electric direct-drive fully submersible water pump with a capacity of 1,000 liters/hour. The Abaco Site Saw Mod S2’s accessories include two side benches with rollers and two support arms with stops.
The dimensions are 82 ¼ x 82 5/8 x 65 3/8 inches (2,090 x 2,100 x 1,660 mm).
A key feature of this system is its ability to use drilling or milling tools, therefore potentially performing radius operations on countertops and complex finishing work on billets (strips). While the saw head is at the 90-degree position, it is equipped to accept core drill bits, finger bits or other milling tools without interference from the blade assembly.
The machine may be equipped with Breton’s innovative photo layout system, and may be fully integrated with the Imagemaster inventory control system. For more complex geometry, a tracing or probing device is available and can be used in conjunction with advanced three-dimensional software that is fully supplied and supported by Breton.
The standard Z travel of the machine is 21.6 inches, allowing for operations on columns and other architectural work that requires lathe turning.
A 45-degree manual inclination disc allows users to miter cut - even when step cutting. The ball bearing linear guides and the new Siemens electric and electronic components allow the saw to operate with optimal precision and reliability.
The spindle slides on an assembly of linear guides and pads. Bridge traverse is on steel guides with ball rollers in an oil bath. Both the spindle motion and bridge motion occurs through a rack-and-pinion system with variable speed.
Spindle lifting occurs on round guides and bronze brushes with screw kinematic motion and variable speed. The disc holding electro-spindle allows for manual slant up to 45 degrees with slant visualization.
The turntable moves on a special ball-bearing pivot block, which can be moved with a full load.
According to Comandulli, particular attention has been devoted to the selection of the electrical control panel parts, resulting in a machine with fast, yet “soft” movements that runs with minimal noise.
The machine is supplied with a water system with solenoid valve and flow-indicator, which stops the machine automatically in case of a lack of water.
An arm-mounted control panel can easily be reached by the operator, along with a push-button panel located directly on the machine. The unit also has a linear laser for material alignment and cut indication.
Options include the following:
- Bench with automatic rotation and precision locking every 45 degrees and electronic positioning on 360 degrees. Bench rotation visualization with control.
- Overturning bench from 0 to 80 degrees with a wood loading platform and hydraulic control unit
- Adjustable disc rotation speed (inverter): 700:2000
- Automatic centralized lubrication
The marine plywood worktable has built-in omni-roller wheels that help to quickly position the slab.
- Blade motor: 10-horsepower, three-phase, 240volt, 60Hz, 1,700 rpm
- Lengthways travel: 11 feet
- Cross travel: 6 feet
- Vertical travel: 9.5 feet
- Standard Blade Diameter: 14 to 18 inches
- Maximum cutting depth: 5.8 inches with an 18-inch blade
- Size: 16 feet (length) x 7.5 feet (width) x 7 feet (height)
- Total weight: 4,850 pounds
- 50-mm arbor
- Horsepower: 10 HP
- Level of automation: Semi-automatic
- Machine size: 18.4 x 7.4 x 6.6 feet
- Control description: Remote swing-arm panel
- Turntable description: Manual rotating worktable with pneumatic stops at 0, 90 and 180 degrees
- Degree of head tilt: 0 to 90 degrees
- Blade size: 16 inches (granite); 20 inches (marble)
- No foundation required
Also, the multifunctional rotating head is programmable and can be personalized for various types of specialty cuts such as curved cuts, profiles, copying templates and pieces drawn with CAD.
A modular design allows the user to customize the Löffler equipment to fit specific shop requirements, from the standard bridge saw to the highly advanced CNC-controlled profile sawing machine with optional router spindle and drilling tools available. The Löffler saws feature built-in material handling equipment for easier job management and greater production facility. Löffler bridge saws also feature automatic cut sequencing, a programmable turntable with thread control, step-cutting at angles from 0 to 45 degrees, two-dimensional and two-and-a-half-dimensional profiling capability plus milling and drilling. Seamlessly connected to the most modern electronic controls available, Löffler digital networking links to the user’s office PC-based programs for complete management and job control. All Löffler equipment works readily with any digital templating system with overhead template projectors. Product training along with ongoing service and support are provided by Fabricator’s Choice.
The bridge saw is programmable and comes complete with a touch-screen control package. A remote control pendant can be used for lateral, vertical and bridge movements. The controls have been designed to be easily understood and simple to operate.
A 25-horsepower, direct-drive blade motor provides cutting speeds of 1 to 17 feet per minute. A laser provides visual aid for cutting path accuracy. The maximum blade diameter is 18 inches, vertical blade travel is 10 inches, bridge blade travel is 12 feet and cutting travel is 11 feet. The unit’s cutting blade head tilts up to 90 degrees. Thanks to its precision components and construction, angle cuts are accurate and easily made.
The EZ Cut features an oversized, heavy-duty 7- x 12-foot manually rotating table with hydraulic tilt and brakes. The hydraulic table tilts 85 degrees and has a 3,300-pound capacity.
The EZ Cut is rated for 208/230-volt, three-phase, 60-HZ operation.
A double-beamed bridge in oversized structural steel moves on cylindrical rollers contained in oiled guides. Rack-and-pinion gearing with helix-shaped teeth ensure smooth movements.
A sliding overhead support is mounted on two oiled and protected cast iron guide saddles of adequate length.
The flat, flanged electric disc chuck manually tilts from 0 to 90 degrees, supported by two well-distanced, large-diameter, chromium-plated circular columns that vertically slide through long tubes built into the same support.
A vertically fixed bench was designed to be easily manually turned on a horizontal plane with any load, thanks to a large-diameter protected fifth wheel. It is hydraulically lockable in any position, along with the fixed positions, by an electric device on the command panel.
The command panel itself is supported by an adjustable arm hinged at the far right of the bridge, with all the necessary commands to control the machine, including the programmer.
The programmer has up to eight different cutting measures, each one repeatable “n” number of times, according to the blade thickness. Automatic cuts are executed on the forward stroke (controlled speed and quick return) or on the forward and reverse stroke (controlled speed on both strokes).
Other accessories are available on request.
The maximum material size processed is 4 x 7.9 x 13 feet (1.2 x 2.4 x 4 m).
The Yukon II can be controlled with the intuitive joystick or the touch-screen computer control. Dual potentiometers allow operators to independently control out-of-stone speed and cutting feed rates. The Yukon II also has 10 programmable cut widths available in the automatic cut mode. With just a touch of the screen, the programming instructions and guidelines can be displayed in either English or Spanish.
A powerful 20-horsepower arbor-drive electric motor powers diamond blades up to 24 inches in diameter. In addition, the 1-horsepower cross-travel motor allows for a rapid traverse rate of 1 to 50 feet per minute. In addition, a laser saw blade alignment indicator improves set-up for long passes.
A new diagnostic screen allows operators to review the machine’s control status while providing helpful, onscreen directions and troubleshooting guidance. Operators also receive Park’s customer service, including the “Next Day or No Pay” parts guarantee and 24-hour troubleshooting customer support, seven days a week.
The GS131 can be equipped with 80 or 100 blades, and the large-dimension battery is connected to the blade frame through two seamless connecting rods that have been created through machining operations of hot rolled steel blocks.
The blade holder frame straight cutting stroke is guided through special maintenance-free articulated units that rotate onto conical roller bearings, thus causing rolling friction only.
The vertical stroke of the block holder platform is driven through four lead nuts that are located onto the structure’s upper side, (i.e. away from the water splash), and it is synchronized through solid connecting shafts.
According to Pedrini, the Arco di Trionfo units offer optimal cutting performances due to the machine’s layout, which allows for continuous and contemporaneous utilization of vertical and horizontal discs.
The M594 works on granite blocks arranged in a single row, and it has a cutting capacity of 13 cubic meters per day. Meanwhile, the M596 works on two rows of blocks, and it has a cutting capacity of 20 cubic meters per day.
The Pedrini Universal M930TG revolving and twisting head NC bridge saw has a 625/700-mm disc diameter capacity to cut and shape building stone, furniture, monuments, countertops, and other elements. The machine has a 500-mm-long vertical stroke and performs step cutting in any tilted position as well as “spatula” cutting.
The numeric control is managed through an industrial PC and a touch-screen color monitor. Brushless motors are used to drive the axis movement.
The head tilts from 0 to 90 degrees and has 0- to 185-degree rotation. The motor can be equipped with a double-locking system for the disc and for vertical axis shaping tools. The cast iron bridge is reinforced by a vertically extended section, and the main slide runs on prismatic guides that are featured by a very large holding base. They are also equipped with a clearance adjustment device.
The M930TG performs square/angular cuts and shaping operations through the rapid interpolation of C axis (head axis rotation on the horizontal plane) with X and Y axes -thus allowing for the elimination of dead time while the bench rotates.
Through imported software, the PC performs curved trajectories on the X, Y and Z axes, and with the inclusion of C-axis interpolation, it offers a broad range of three-dimensional stone processing.
The large, rigid trolley assembly provides the Universal M960TG with exclusive features such as the capacity to use 900-mm-diameter discs, a 700-mm-long vertical stroke, the possibility to perform the step cutting in any head tilted position and a “spatula” cutting system.
The tool head has 0- to 90-degree tilting capacity with automatic lock in any position, along with revolving capacity from -15 to +365 degrees. The tool head is prepared to house an independent electro-spindle for vertical axis shaping tools.
The PC controls up to seven axes and performs the linear interpolation of X, Y, and Z axes as well as the circular interpolation of two axes.
With a stationary workpiece, M960TG performs square and angular cuts as well as electro-spindle-shaping operations through the rapid interpolation of C axis (head axis rotation on horizontal plane) with the X and Y axes.
With ISO code programs, the PC performs curved trajectories on the X, Y and Z axes, including the interpolation of C axis.
The machine has been engineered to be easy to use, as it has been equipped with AutoCAD with a CNC and PLC control system that guarantees maximum cutting precision, Pellegrini reports.
The Diamantfil Jolly has also been designed for maximum flexibility, allowing for block squaring and block slabbing with an automatic cutting cycle up to 1,000 cuts in variable thickness with automatic control process.
The machine is equipped with an electrical trolley with a 40-ton capacity as standard equipment, but depending on the blocks to be processed, it is also available with a 60-ton-capacity trolley.
The machine has variable diamond wire speed, which allows the user to set the ideal cutting parameters for any type of stone, and the patented Multi-Pull® electro-hydraulic wire tension system ensures ideal tension in each wire. This, together with the large-diameter flywheels, ensures long diamond wire life and fast, accurate cutting, the company reports. By cutting with diamond wire, the resulting slabs polish quickly and easily, according to the company, and the machine offers a quick turnaround time between blocks.
Pellegrini reports that the foundation of the machine is simple and low-cost, as operators simply need to ensure that the block carriages are under a gantry crane of adequate capacity. Additionally, if the local climate allows, the machine can be installed outdoors, thus eliminating the need for a building.
- Approximate production rate: 10 feet in 50 seconds in 1 ¼-inch stone
- Blade diameter: 16 to 24 inches
- Maximum cutting thickness using a 24-inch blade: 8 inches
- Maximum cutting length: 10.5 feet
- Blade motor power: 20 horsepower
- Blade rotation: 1440 rpm
- Automatic plunge tilting head: 0 to 45 degrees
- Transformer supplied to convert 380-volt 3-phase power to 220-volt 3-phase (40-hp) 60 amps
- Water consumption: 5 gallons per minute
- Beams bathed in oil with protective housing on all four beams
- Blade-bearing slide feed with electric drive
- Approximate loading capacity of table: 1,320 pounds
- Size: 9 feet long x 16 feet wide x 11 feet high
- Approximate total weight: 17,500 pounds
With a unique three-side-open gantry and hydraulic table tilt, the SX5 is easy to load. With an intelligent speed regulator, the SX5 can be left to work. No operator is required to monitor the machine during single or multiple cuts, as the full-programmed shape will be cut without the need for adjustments. The saw can also be switched to manual mode for simple sawing operations.
Like all of Scandinvent’s CNC machines, the SX5 comes with ScandSOFT software, allowing users to cut shapes automatically, in one program. Among other benefits, ScandSOFT allows the actual slabs being used to be photographed and imported into the CAD program. This allows the proposed cut-outs to be virtually arranged in the program, on top of the photo of the actual slab. The image can be printed for final approval, and the customer can review the stone patterns, fissures, anomalies or defects in the stone before cutting.
The GMM Eura is a versatile bridge sawing machine equally compatible with small workshops as well as large plants. It is designed to be easy to use, compact and efficient. This versatile sawing machine is uniquely suited for small jobs as well as handling the most demanding production output. All operations can be executed manually or automatically by the easy-to-use Multicut program, which is capable of processing parallel cuts with fixed dimensions - repeatable up to 99 times.
The Rotex features cuts from CAD and Slab-Cam technology, which puts the operator in complete control of the sawing process from fast accurate set-up to increasing production to reducing waste.
The Brio does not utilize masonry wall foundations, making it compact and very cost-effective to install.
The TC04 N also allows easy and extremely accurate cuts in materials up to 200 mm (8 inches) thick.
- Maximum blade diameter: 625 mm (24.60 inches)
- Tilting head 0 to 100 degrees
- Z stroke: 350 mm (13.77 inches)
- Longitudinal railway (Y axis): maximum of 12.14 feet
- Transversal movement (X axis): capacity of 7.21 feet
- Disc motor power: 10 to 17.6 kw (14 to 24 horsepower)
The machine accepts blade diameters up to 750 mm (29.53 inches) and a granite-covered table measuring approximately 11. 81 x 6.56 feet, which can be installed.
The 4-axis CNC gantry saw combines high technology with user-friendly CAD/CAM software, delivering increased productivity and numerous processing options. With the Skema C-180, the user has full control of drawings and processing of shapes and profiles with the blade on vertical, inclined or horizontal positions. The convenient control panel, mounted on a swiveling arm, includes serial and USB ports. Projects can be loaded into memory, and the machine does the work.
Stoneworking CentersThe Ghines Systar multifunction workstation, available from Alpha Professional Tools, was conceived as a simple and performing solution for fabricating the most frequent jobs. It is capable of shaping and polishing internal and external contours (with or without a template). It can also be used for every kind of profile; holes, sink cut-outs, recessed drains, grooves (inclined or flat), slots on edges, etc.
The operating head - driven by a powerful and reliable electro-spindle - works with internal and external lubrication. The double lubrication, together with an extreme ease in changing the tool holder, allows the use of many kinds of tools. The Systar operating head is set on high-precision orthogonal guides, and three digital displays show the tool position on the X, Y and Z axes in real time.
The machine has been designed to be easy to install, and it does not require any masonry.
Other applications are also possible using the Coch R30, including drilling of faucets holes, surface polishing and edge polishing.
Virtually any CNC or router bit will fit on the FabMaster. The variable-speed spindle is adjustable from 1,000 to 10,000 rpm, and it is digitally displayed on the touch screen. One of the key features of the FabMaster is the programmable head oscillation, which is useful when polishing and milling. Another notable feature is that the table height is adjustable, which allows the fabricator to parallel the stone to the beam before edge profiling. Also, users can adjust the table height for drain board cutting and fluting. There are no hand cranks on this machine, as it has fully motorized up/down (Z-axis) positioning, along with the adjustable vacuum support rails. The product also features center and bit flood water feeds, adjustable water flow.
Formatted as the Löffler 1 MachineTM, it is also a fully automated machine center version that allows wet cutting of stone or solid surface for shops streamlining operations or expanding product offerings. Löffler CNC machines feature high-quality ball rail systems, high-precision ball screws and digital servo drives for the X, Y and Z axes. A fourth axis is available as an option. The tool rack has 44 stations. The units also feature variable-speed electro-spindles and automatic tilting spindles up to 2 degrees for drain board processing.
LBZ Series CNCs are built as modular designs and are supplied to meet specific operational requirements. The highest level of shop automation is available with Löffler Galileo DesignerTM software, making machine parameters such as tool selection, feed speed, tool delivery and in-and-out paths automatically generated. All Löffler equipment works with digital templating systems and template projectors. Löffler equipment is supported by Fabricator’s Choice training programs, ongoing service and support.
The FabCenter, built on the SW 138 Stone Router platform, is Northwood’s latest innovation, and it was designed to provide an affordable, yet high-tech solution for smaller shops that process as little as four or five slabs per day.
The overall concept was to allow small shops to join the “digital revolution” and build a kitchen using one machine from start to finish. This technology revolution starts with Northwood custom software, StoneVision. The digital template is imported into StoneVision, allowing for 100% digital operation with no need for mylar templating. When coupled with Slabsmith software, users can digitally lay out and grain-match each slab without leaving the office. Born from technology and lessons learned with the introduction of Northwood’s SawJetTM, the StoneVision software automatically tool-paths the parts to be cut. The cutting process begins with the slab saw, powered by a Fanuc-drive, extreme-duty spindle. All straight edges are cut with the slab saw, and all radius cuts are done with the with the finger bit, providing a complete cutting process. Pods are then placed on the table with the help of the unit’s laser pod and part placement system. Edges are processed and polished in one setup with the proven EDS (Extreme Duty Spindle).
The CTEC 3A is a CNC milling machine with an automatic tool changer for fast and precise processing of granite, marble and other stones. A 20-position tool holder is standard, and the machine uses ISO40 conical tool holders.
Movements of the three axes (X, Y, Z) are on precision linear guides and ball bearing screws. A powerful 7.5-horsepower motor at 6,000 rpms allows deep cuts in the toughest of stones. Oversized workpieces can be machined on the CTEC 3A’s large 144- x 63-inch worktable.
The machine also includes floating vacuum cups that help reduce set-up time. These rapid set-up features intend to reduce set-up time by up to 80%.
At 1,800 mm per minute for edge work, the unit can process a 3- x 8-foot countertop in about an hour and a half, the company reports. In addition, it is versatile enough to sequentially process up to four sink vanities in one set-up, maximizing processing time.
The C-TEC3A operates using 220-volt power. It also uses filtered, reclaimed water throughout, eliminating the need for fresh water.
Meanwhile, the high-power Gantry Vertical coring machine can create large bathtubs out of solid boulders of stone. All of the coring bits produced by Ogyu are equipped with diamond segments attached by a special soldering technique that allows for optimum durability and longevity, enhanced by tall segment chips.
Coring bits with diameters ranging from 50 to 1,600 mm are always available, and smaller or larger bits can be custom made.
The workable space for curve cutting is within a radius of 750 mm from the center of turning table, except within a radius of 150 mm from the center.
The Digit-All’s footprint also conserves shop space when compared to dual zone or shuttle table CNC systems, according to Park. With just a few simple steps, fabricators can completely fabricate an entire slab at one station with finger-push part positioning.
The Titan was designed to be fast and easy, as operators can call up programs using a point-and-click method with a bar code reader. An overhead laser projects where the vacuum pods should be placed on the table, with precise accuracy. After the pod placement, the operator starts the sawing cycle. An independently controlled CNC saw dimensions natural stone or quartz material slabs with extraordinary accuracy. After the parts have all been separated on the slab, the edge-finishing program is called up by bar code, and the parts are floated into position by reverse vacuum airflow. One operator can effortlessly guide the common-line cut separated parts to their edge-finishing location using the guidance from the overhead laser. There is no need for a second worktable or a material handling system. The parts are then ready for shaping and edge polishing.
For smaller shops, this concept allows fabricators to produce kitchens with just one machine. For medium to larger shops, the Titan Digit-All CNC SlabCenter gives fabricators the flexibility to route their job flow processes based upon their production schedule. The machine also provides the peace-of-mind to schedule machine maintenance on other machines without impacting a production schedule.
Users can quickly convert templates into accurate machine code with point-and-click simplicity directly at the machine, due to an on-board laser digitizing system. Alternatively, users can convert and program from the standard electronic DXF files at the control unit with the TouchStone programming system.
The machine can cut at a rate of 2,360 inches per minute, or more, with the 24-horsepower, variable-speed spindle drive system that runs up to 10,000 rpm. An optional 3-horsepower saw blade drive with its own precision slide system is available for complete, programmable 360-degree continuous rotation.
The automatic tool changer was designed to get to the right tool position quickly, and it also washes the tool holders between every change for less wear, less operator intervention and a better grip. There’s also a smart sensor that prevents putting a tool back into a full pocket, and a laser tool management system measures and accommodates for tool wear, prolonging the life of your tools and saving operator set-up time.
The Titan’s HyperdriveTM precision-ground, helical rack-and-pinion drive maximizes tool life and improves cut quality (accurate to .0004 inches in 13 feet of travel). The fast acceleration and deceleration makes for quick tool changes. Plus, the smooth, quiet operation and easy maintenance makes the Titan easier on the operator.
The C4 features an open gantry with a compact and space-saving design that allows for any size workpiece. The stone is worked “polished side up” to make set-up easier, and a “tilt table” means your stone does not need to be calibrated and helps in the production of drainers and flutes.
The entire process is run from an integrated PC Windows control panel. The user-friendly interface in the computer makes it possible to draw, change and save thousands of drawings and figures at the machine without any knowledge of CNC technique, the company reports.
The machine includes CnCutCam, user-friendly software to make CNC programs of any sink, cooktop or solid stone shower trays. More complex operations are possible with higher CAD/CAM experience levels. The machine has a 15-position tool changer, and a 12.5-horsepower spindle motor that allows for the use of standard CNC finger bits.
In engineering the machine, Omag has integrated simple operation with complex output capabilities. The software package is PC compatible, for use with Omag-customized CAD/CAM programs. The controls have been designed to be easy to learn and simple to operate, making it well-suited for both single-unit production and large-scale manufacturing applications.
- Table Dimensions: 10 feet, 8 inches x 5 feet
- X axis (transversal): 10 feet, 5 inches
- Y axis (longitudinal): 8 feet, 2 inches
- Z axis (vertical): 23.62 inches
- T axis (tilting): 0 to 28 degrees
- Spindle Rotation: 0 to 9,000
- Spindle Power: 11 Kw, 15 hp
- Installed Power: 26 Kw
- Tool Storage: 40-ISO50
This new machine, with its reduced dimensions and unusual design, fills specific market requirements. It was engineered as an easy-to-use and innovative CNC workcenter with a touch-screen and lateral door to the tool magazine. The patented front door also makes for easy loading/unloading of pieces.
The tool magazine has space for 32 tools, and the axis strokes are 10.18 x 5.38 x 1.3 feet.
With high capacities (11.2 x 6.1 feet) and a Z stroke of 2.7 feet, large-scale jobs can be achieved. The tool magazine can hold up to 47 different tools.
The T858 is available on welded or concrete structural plinths in two lengths - 19.6 and 39.4 feet - with one or two work areas. The new controller includes the very latest generation of software for using five axes.
CNC AccessoriesBonded tubing from Blick Industries was developed to help fabricators prevent their suction cup tubing from becoming a tangled mess. Two polyurethane tubes bonded together to provide an easy solution to organization. This tubing, coupled with a few Blick Industries tube mats, intends to leave the worktable neat and organized.
According to Breton, under normal conditions, the manual process of hand positioning suction cups, connecting hoses and actuating the vacuum depending on the layout can take as little as 15 minutes and as much as 45 minutes or more. The Robocup can perform a full change of 18 pods in less than six minutes.
By normalizing the setup cycle, Robocup facilitates a full range of robotic loading solutions. Breton expects this system will appeal to CNC prospects wishing to maximize daily footage produced by reducing idle time and minimizing manual intervention.
Edging MachineryThe Hercules edge-profiling machines from Braxton-Bragg, LLC are available in variable-, double- and single-speed models with an optional hydroplaning or roller system base. All models will quickly and safely mill and shape the edges of slabs of marble, granite or other stone materials in various profiles and thicknesses. They accept virtually all brands of bits and come standard with a 22-mm shaft for the tool holder and 10-mm female thread. Hercules edge-profiling machines come with a six-month warranty, ground fault interrupter and a built-in quick disconnect fitting to attach to the water supply.
The Goldenedge CTX/V is capable of full three-axis operations within the 11.8-inch Y axis travel of the machine. This allows full speed finger-bit details and both inside and outside radius, bump-outs and every commercially available CNC tooling profile.
In operating the machine, the user simply places the cut-to-size piece against a mechanical guide. The pneumatic “pressers” are engaged for work-holding and the operator then simply runs the program. This new version of the Goldenedge incorporates an optional straight V-grooving aggregate to execute the V-grooved “box” edges that have become popular in the U.S. This inline machine will appeal to fabrication shops that seek to match CNC quality polishes within the same project or to maximize throughput on their full-size CNC on straight pieces or those that can be seamed after a 3-inch return, with a lower investment and less floor space than a full-size CNC stoneworking center, without the need of a programmer.
The ball bearing linear guides and the new Siemens electric and electronic components allow for optimal precision.
The profiling and polishing operations of the LF12T are carried out in one single automatic operation managed by the PLC. Material is placed on a motorized belt, and goes through a sequence of gauging, pre-shaping, profiling, polishing, beveling and cutting spindles.
The Omega 100 has a heavy-duty roller conveyor system like the Omega 60. This system ensures no slab slippage and no loss of production. Also, mixed slab thicknesses can be processed without having to change tooling (for flat edges). The section containing the oscillating polishing spindles is actuated by a sealed oil bath mechanism, which is located on each side of the beam and ensures smoother motion and less maintenance, according to the company.
These machines are available in U.S., Canada and Mexico exclusively from Comandulli USA of Houston, TX.
The Penta has many features that not only ensure a good finish, but reduce the maintenance requirements of the machine, according to the company. These include slab locking by pneumatic pistons, electrical spindle motors and conveyor belts supported by a stainless machine base that ensures no slab slippage and little maintenance.
The Spira was designed as a simple machine in terms of mechanical components and electrical and electronic equipment as well as its ease of use.
The machine is capable of calibrating (maximum size of 50 mm), polishing of straight edges, upper and lower 45-degree bevels, upper and lower pencil round profiles and lower/upper grooves.
The machine features a conveyor belt driven by a stainless steel plane; pneumatic slab-holding pistons, a control panel with a touch-screen visualized keyboard; main covers in stainless steel; a water-collecting tank with lateral flows; and an electronic system that controls the advancement, rotation and descent of the holding slab piston - only when the slab passes - without any other lever mechanism with sensory device.
The units can be used for milling and grinding sinks, kitchen countertops, vanities and tables. The rotating contact ring on the diamond profile tool enables accurate profiles to be made without any aiding constructions, and the machine can be used for both straight and curved edges. (Caution: For safety reasons, this unit should be operated only in conjunction with the GFI operator protection circuit breaker.)
The KSL 100 MG receives granite and marble up to 130 mm thick, has six planetary heads, two upper and two lower chamfering heads plus one PF/EL profile milling and sawing unit precisely controllable from the LCD control panel.
Löffler Vario edge processors can be integrated with Löffler CNC equipment stations via Löffler-designed conveyors to facilitate workflow or can fit into existing equipment systems to improve shop performance. Options include flexible bellows to provide optimal protection on the guide rail and various table extensions designed to a shop’s specific configuration requirements. Product training plus ongoing service and support are provided by Fabricator’s Choice.
The ECO-BL has a carriage that is driven by a system of levers and rods, on which are mounted five shaping/polishing units driven by hydraulic motors. The shaping of the bullnose edges does not require shaped wheels because it is carried out with a common diamond flat wheel. The continuous movement of the abrasive on the shaped edge during polishing allows excellent finishes to be achieved. The carriage can be locked into any position to make inclined edges.
The rotation of the carriage is also accomplished by means of levers and rods, which are driven by a system that employs highly resistant cog belts and a single-gear motor. Meanwhile, the belt’s sliding surface is plated with anti-wear stainless steel. All versions of the ECO-BL feature a self-diagnostic computerized control system. The control and positioning of all moving parts are performed completely automatically by the computerized system.
The LVP-9 polishes straight flat-squared marble or granite edges ranging from 1 to 6 cm thick. It also automatically chamfers upper and lower edges if desired.
Production speeds are up to 100 lineal feet per hour, the company reports, and edge processing is continuous. Different pieces can be inserted sequentially and move past a series of mandrels so that they come out completely finished.
Granite and marble slabs are vertically inserted into the LVP-9. Handling slabs vertically not only reduces the possibility of material breakage, it also considerably reduces the floor space and work area requirements, according to Marmo Machinery USA.
The LVP-9 was designed to be easy to operate. The operator simply turns on power to the various polishing heads; the pressure bar is applied to the desired thickness; the workpiece to be polished is loaded; and the pressure of the various polishing heads is adjusted. Finally, the conveyor belt is turned on and adjusted for speed.
This machine has a carriage that is driven by a system of levers and rods, on which are mounted six shaping/polishing units driven by hydraulic motors. The shaping of the bullnose edges does not require shaped wheels because it is carried out with a common diamond flat wheel. The continuous movement of the abrasive on the shaped edge during polishing allows excellent finishes to be achieved. The carriage can be locked into any position to make inclined edges.
The rotation of the carriage is accomplished by means of levers and rods driven by an innovative and unique system that employs highly resistant cog belts and a single gear motor. The belt’s sliding surface is plated with anti-wear stainless steel.
All versions feature a self-diagnostic computerized control system. The control and positioning of all moving parts are performed completely automatically by the computerized system. The MAXI-BL is monolithic in shape, sandblasted, painted and oven dried.
The first step is polishing and edge chamfering plus the V-shape milling at 90 degrees with two mandrels that are adjustable in height and depth - one at the entrance and the other at the exit. These bear two V-shaped diamond wheels, the first one has a rough grain for the pre-cut, and the second one has a fine grain for refining the first cut.
For the second step, outside the machine, the two portions of slab can be glued along the inclined sides of the 45-degree milling. Meanwhile, for the third step, the L-shaped piece can be refined and chamfered by the same machine along the external gluing line, laying the larger portion on the conveyor belt and vertically inserting the smaller portion between the rubber rollers and the abrasives. This way, the lower chamfer can refine the edge.
In the standard version, this edge polisher can be equipped with one incoming calibrating/drip-cut unit, one outgoing shaping/drip-cut unit or both.
The LCV does not require either a foundation or special inclination for water discharge. It can be simply placed on the ground, and as it is completely streamlined, the discharged water can be easily directed to a point at some distance, by means of a hose connected to a special drain.
This edge polisher is available in four standard models:
- LCV 711 M : seven polishing heads, two chamfering mandrels at 45 degrees
- LCV 711 M-SE: seven polishing heads, two chamfering mandrels at 45 degrees, one incoming calibrating/drip-cut unit
- LCV 711 M-SU: seven polishing heads, two chamfering mandrels at 45 degrees, one outgoing shaping/drip-cut unit
- LCV 711 M-SE/SU: seven polishing heads, two chamfering mandrels at 45 degrees, one incoming calibrating/drip-cut unit, one outgoing shaping/drip-cut unit.
Among its outstanding features, the LTH is equipped with the micro-oscillating of the polishing mandrels, usable either for the flat edges or for flat portions of edges, such as between two rounded corners. It also features automatic positioning of the first and second auto-shaping diamond wheels and electronic action of the pneumatic mandrels.
The standard LTH model is composed of one incoming calibrating/drip-cut mandrel, two chamfering mandrels inclined at 45 degrees (equipped with a mechanical stop) and seven oscillating polishing mandrels for 150-mm wheels (the first two of which are equipped with a mechanical stop for the cup-shaped auto-shaping diamond wheels). New models with the addition of other mandrels can be supplied if requested. <
The LTT was designed for optimal reliability, due to mechanisms such as an oscillating system that operates by means of levers and connecting rods. The compact length of 3,930 mm, coupled with affordability, are suited for shops looking for standard productivity.
The LTT is equipped with one incoming calibrating/drip-cut mandrel, two chamfering mandrels inclined at 45 degrees (equipped with a mechanical stop) and six oscillating polishing mandrels for 130-mm wheels (the first of which is equipped with a mechanical stop for the cup-shaped, auto-shaping diamond wheel). New models, which derive from the standard LTT 621 model with the addition of other mandrels, can be supplied if requested.
The LTV was designed for optimal reliability, due to mechanisms such as an oscillating system that operates by means of levers and connecting rods. A compact size of 4,100 mm long and 1,300 mm deep, (only 4100 mm length and 1300 mm depth) in combination with an affordability platform, are suited for shops looking for standard productivity.
The LTV is equipped with one incoming calibrating/drip-cut mandrel, two chamfering mandrels inclined at 45 degrees (equipped with a mechanical stop) and six oscillating polishing mandrels for 130-mm wheels (the first of which is equipped with a mechanical stop for the cup-shaped, auto-shaping diamond wheel).
The Fastback can manage material ranging from 1 to 6 cm thick, 16 inches to 12 feet long, and 3 to 30 inches wide (wider stones possible with operator assistance). The unit can produce straight flat edges to a 45-degree chamfer at the top and bottom edge corners up to 1/16 inches, and it can fabricate a 3-cm medium/hard granite with a flat edge (1/16-inch chamfer) at a rate of 12 inches per minute. The spindle oscillating heads are engineered to produce an exceptional overall finish and eliminate any lines.
The 21 spring-loaded, non-marring clamping rollers with manual crank adjustments allow operators to control the pressure on the stone against the conveyor. The powered conveyor is 13 ½ inches wide x 8 feet, 10 inches long, with 7-foot in-feed and discharge conveyors that are engineered with rollers and guide fences that support the material.
The Park Fastback flat edge shaper and polisher offers fabricators optimal finish quality, heavy-duty performance and precision operation. Operators also receive Park’s customer service, including “Next Day or No Pay” parts guarantee and 24-hour troubleshooting customer support, seven days a week.
- Overall dimensions: 13 feet, 8 inches x 6 feet, 5 inches (4,160 x 1,920 mm)
- Useful working length: Limitless
- Useful working width: 7 inches to 17 feet, 4 inches (180 to 2,200 mm)
- Useful working thickness: 15 to 40 mm (bullnose); 10 to 40 mm (straight edge)
- Production speed per minute: 6 to 78 inches (150 to 2,000 mm)
- Total power (kW/Hp) 20 kW/27 horsepower
- Maximum water consumption: 80 liters/minute
- Maximum air consumption: 100 liters/minute
- Weight: 8,140 pounds (3,700 kg)
Standard features include: a touch-screen control panel that comes pre-programmed with eight standard edges and the capacity to store and save up to five customized programs per edge with a working thickness of ¾ inch to 4 inches; a seamless eight-position rapid automatic tool changer; heavy rollers to quickly and easily load and unload workpieces; a state-of-the-art vacuum table to secure job pieces to the workbench; and a water-secure, 3-horsepower hydraulic spindle motor affixed to a precision heavy-duty C frame. This machine was engineered to produce up to 400 feet of flat edge or 130 feet of full bullnose per shift. Users can enhance the performance of the machine by adding the optional quick-attach system for narrow backsplash jobs and the extra side tables to accommodate the widest job pieces. The Edgetec 3500 is professionally installed and serviced by the factory-trained technicians at Regent Machine Corp. directly from its East and West Coast service centers.
- Spindle power: 3 horsepower
- Maximum workable length: 11.66 feet
- Thickness range: 3/8 to 4 inches
- Automatic tool changer: 8 positions
- Height of worktable: 38 inches
- Dimensions:181.6 inches (length) x 56 inches (depth) x 53.6 inches (height)
This highly productive machine features the patented Proportional Control Pressure (PCP), which maintains consistent polishing pressure along the whole profile and is well suited for thinner or more delicate pieces. This allows the Quasar Tech to produce profiles with an optimal level of quality. It can also process a wide variety of profiles and flat edges, and it will even make the initial cut on an ogee edge.
Surface PolishingBorn from Breton’s extensive background in developing the Levibreton KG and KLG series of slab polishing solutions for our slab producers, the company has developed a new machine to bring these capabilities to the smaller fabricator or localized suppliers.
Breton’s new Levibreton One is a single-head bridge polishing and texturing system designed specifically for lower-volume slab processors or the mid- to high-volume fabrication shop to expand their product offerings to include antiqued, honed and other specialty finishes to customers in virtually any material.
The machine is capable of texturing, polishing or re-polishing full slabs up to 138 x 86 inches as well as individual cut-to-size pieces via a simple mechanical location system.
Driven by a rigid cast iron-housed, 19-horsepower spindle, which rides along a cast iron bridge, the 17.7-inch-diameter oscillating head for granite will accept a set of six tilting “brick”-style abrasive segments, which can be manually changed according to the desired effect. Other head styles are also available.
The Levibreton One is equipped with a very simple PLC control, which allows the user to easily define size and location of the material and then select one of five polishing patterns. This machine is expected to appeal to those shops who wish to have better variety and availability of finishes for their customers or who might wish to outsource this capability.
The P7G gantry slab polisher is equipped with an automatic grit exchange, automatic sensing for different thicknesses of slabs and automatic pressure regulation. Ogyu reports that the machine can quickly achieve a high-gloss polish through rotary turning of seven kinds of polishing wheels, and it can process workpieces with five different thicknesses automatically. A simple manual polishing machine is also available.
The transversal movement of the beam is driven by an extensively tested “gearless” transmission that works into protected dry housings inside the bridges. This moves the beam smoothly and maintenance free, and it does not harm the mobile beam with additional weight.
The polishing heads are operated by Pedrini’s patented direct-drive rotor spindles that work without transmission belts. The rotor spindles are further equipped with an easy-to-use individual device for precise centering to the processing plane that provides the best operating conditions for the abrasives - with minimal tool consumption and high processing quality. The machine’s automation is managed through soft logic on the Windows NT operational system.
Through a simple interface, the operator controls and programs all functions, including minimal lift of the heads upon outlet of the slabs and quick head lowers as slabs enter the line - all while keeping the working pressure unchanged.
Plants for processing particularly brittle stones are equipped with a station for application of the reinforcement netting, and with a vacuum chamber where depression allows the air bubbles to quickly exit the material, thus improving resin penetration.
This compact monoblock machine was engineered to be easy to use and quickly installed. It features a working capacity of 3,500 x 2,200 mm, and it has a magazine with 10 tool spaces. With the T 508, users can combine different finishes, depending on customer requests, and they can also develop new finishes.
The T500 is available in two distinct sizes - 7.21 feet and 10.40 feet, and it was conceived as a simple solution to offer a texturing service to customers. Finishes for custom slabs can include bushhammered, antiqued, brushed, honed and others.
The machine can also be used for concrete panels, polishing of petrified wood, calibrating and many other uses. It is also possible to polish convex or concave surfaces, as well as odd-shaped pieces (round tables, etc).
Waterjet TechnologyBreton’s waterjet/bridge combination - “Combicut” - is in its fourth year of production since its initial release in late 2005, and the company reports that the machine has established itself as a mainstay in its extensive saw product line.
The Combicut combines a U.S.-made KMT 60,000-psi waterjet system with its well-established CNC bridgesaw, using photographic layout technology and software first released in early 2005. Breton’s concept to combine the high speed, efficiency and lower cost operation of a bridge saw for straight cuts, with the flexibility of a waterjet for radius and other more complex-shaped work has proven to become quite popular globally.
Key design features of the Combicut are its massive dual-supported bridge structure, Breton’s cast iron-housed, 23-horsepower spindle and the innovative “Combicam” software, which employs extremely simple layout tools, automatic tool pathing and automatic nesting. The machine is UL certified and is configured with a full enclosure as recommended by OSHA, thus providing superior sound and flying debris protection for the owner’s staff.
Combicut is offered either as a single standalone machine or with a unique automatic worktop exchanger, which eliminates the need for multiple tanks and related maintenance. It also allows the loading and unloading of projects completely outside the work zone of the machine and automates the photography process. The machine design allows for fully automatic slab loading and unloading operations.
Combicut was intended to appeal to fabrication shops that require capacity for complex shapes and desire to produce a high volume of complete cut pieces with minimal hand router or CNC work.
Cuts require approximately 1 gallon per minute of recycled water with optimal accuracy and no diamond tooling. All movements are precisely controlled by a user-friendly CNC. The machine has a welded steel frame and working table dimensions of 10.5 x 6.5 feet, capable of handling a load with maximum dimensions of 9.8 x 5.2 feet. Linear guideways provide axis movement and are powered by precision ball bearing screws.
Other specifications include a weight of 6,834 pounds, a 50-horsepower pump motor and 220/380-volt, 50/60 HZ electrical power requirements.
Beginning in early 2009, all Mitsubishi waterjets will be manufactured in America. The company reports that the new Mitsubishi waterjet facility, located in Wixom, MI, will help control costs, allowing these machines to be more competitively priced. Additionally, the close proximity to Mitsubishi’s corporate headquarters in Chicago, IL, will ensure better quality control and provide the ability to make faster upgrades and modifications to machine design.
The Mitsubishi 700 Series CNC control delivers advanced programming capabilities for high-precision machining and optimal productivity. The unit is controlled on a 15-inch waterproof screen, with improved graphics and NC design to simplify operation.
New features and benefits
- New machine base design with 22-inch I-beam construction
- 40-mm NSK ball screws
- Stainless steel work tank is completely isolated from machine frame
- More rugged and accurate new bridge design
- Pump control completely incorporated into the NC cabinet
- New crash protection that works on the X, Y and Z axes
- Auto grease system for ball screw lubrication
- New worktable design, where slates are located by slots, but the height is set by a solid indicated flat bar
- Redesigned ITC (Intelligent Taper Control) is more accurate and robust, with focus tube length of 76 mm
- New HMI (Human Machine Interface) allows for easier use of the control graphics
The FusionTM 4000 CNC saw/waterjet is designed and manufactured with a smaller footprint. This design allows table access from the front or the side, resulting in much more efficient material flow and greater machine productivity, according to Park Industries.
The Fusion’s dynamic CNC duo results in faster cuts, lower production and labor costs and greater uptime. One sawing head does double duty. The saw makes fast, straight cuts, and the waterjet cuts complex curves with precision. The diamond blade cuts up to 180 inches per minute, while the waterjet cuts up to 17 inches per minute.
The easy touch-screen interface for the Siemens 840Di CNC control unit intends to make the Fusion easy to operate. Users simply position the material and scan a bar code, and the machine begins fabricating.
The Fusion 4000 includes Park’s exclusive HyperDriveTM System, featuring dual, digitally synchronized servo motors that drive precision-ground helical gears flawlessly across a hardened rack-and-pinion system. In addition, the Nested Base Stone FabricationTM utilizes common line cutting strategy, which intends to reduce fabrication time and increase stone yield by nearly 10%. Meanwhile, the KerfPathTM Cutting Cycle blends the cuts between the saw and waterjet for significant labor, machine and consumable savings during down-stream production, Park reports.
A dual-tank option is available. The Fusion 4200 has the same power and features of the Fusion 4000, and a second table allows fabricators to load the stone for maximum machine productivity.