TWO-COLUMN BAND SAW MACHINES FOR VERTICAL CUTS:     

700x750 HERKULES X-CNC

A highly productive automatic, hydraulically manipulated two column band saw machine with a material feeder. The machine uses the extremely robust construction and the arm which is 25 degrees sloped.
X version in the basic solution offers 64-bits control system with posibilities of  automatic regulation of the arm movement towards the cut that  depends on cut resistance of the material, electronic setting of  upper and down position of the arm, on display you can see cutting speed. The control system is prepared for comunication with other external accesories.
The machine is designed for vertical cuts.
It is suitable for serial production in industrial premises. Thank to its robust construction enables to cut wide range of materials including full materials stainless steels and tool steels.

Construction:

• The band saw machine has a robust construction which determines Herkules machines for use of carbide blades. The machine is designed so that it answers the extreme exposure in production conditions.
• Tough frame of machine with columns situated as near the clamping vice as possible minimizes vibrations and enables max. cutting performance.
• An arm is a rugged weldment and it is designed so that a toughtness and a precision of cut was secured. 
• Arm moves on  two columns by a help of  a four row linear leading with a high loading capacity.  Arm movement by a help of two hydraulic cylinders. .
• The robust steel pulleys sloped of 25 degrees regarding the level of the cut. Thanks to sloped arm the twist of the blade is eliminated and these is possibility to bring the blade closer to the minimal distance from the linear leading on columns. This arrangement eliminates vibrations and enables the max. cutting performance of the machine
• The arm of the machine uses the incremental sensor to evaluate the cutting feed and hight of the blade above the vice level.
• Working positions of the arm : the end switch to set the down position. the upper working position of the arm is set automatically by an optic sensor which is situated under the blade. The arm of the machine moves by a cutting feed after starting of every cut. It is possible to activate the speed feed of the arm in manual regime only. This minimalizes the human error of the error of the miscroswitch.
• The vice uses the advanced construction with the long stroke hydraulic cylinder and the jaw situated on the linear leading.  Main vice with divided jaw that clamps the material in front of as well as behind the cut . The optimalization of the chip movement through the firm jaw directly to the chip extractor.
• Both vices ( main vice and feeder vice) are robust steel weldments. Jaws ensure safe clamping of the material.  Jaws move on two rails of linear leading thanks to hydraulic cylinder. One jaw is longstroke ( the movement by longstroke hydraulic cylinder), one is shortstroke (it releases its position when feeding the bar, the jaw is not worn out, the material does not slip). Shortroke jaw of he feeder and main vice with the short stroke rebound, it means contactless feeding of the crooked material.
• Very rigid feeder with the feeding step 700 mm moves on four rails of the linear leading by  hydraulic cylinders. There are two speeds of the feeder (miscro feed when approaching the position). Incrementally straight sensor for indication of the position of the feeder and GTO (go to position) function. 
• The roller conveyer goes through the whole machine and supports the material in all its lenght. The roller conveyer of the feeder : bearings houses of the rollers are mounted into the basement – big robustness and precision.
• Electro-hydraulical equipement of a blade tension with an end switch ensures a constant tension and enables to keep ideal cut conditions. 
• Adjustable quides with hardmetal plates and upper blade leading  by a harden ring on a needle bearing. 
• A cleaning brush is driven by an electroengine and ensures perfect cleaning of a blade.
• There is a planet gear box drive and a three-phase electroengine, a fluent regulation of a circumferential blade speed  by a frequency converter for a fluent change of blade speed. Attention: Drive with planet gearbox coresponds with drive with worm grearbox and engine of cca double multiple power.
• Cooling system for emulsion, leaded to the quides of the blade and by LocLine system directly to the cut groove.
• Robust base with a tank for chips and with a worm chip extraktor.
• Indication of  blade tightening and opening of the cover.
• Control terminal with a microprocessor, control 24V.
• The machine is equipped by the controlling MAHLER terminal, which controls the cut of the machine in two basic regimes : BIMETAL and CARBIDE.
• BIMETAL regime is suitable for optimalization of the cutting feed when cutting profiles by bimetal blades. The cutting feed is realized by PEGAS ARP system which automatically regulates cutting feed depending on the resistance of the material. The cutting feed is higher if the blade cuts sides of the prifile. As the blades reaches the full material, the system reduces the cutting feed automatically so that teeth gap of the blade would not be filled.
• CARBIDE regime is suitable for cutting of full bars by bimetal or carbide blades.  The controlling system regulates the cutting feed automatically ( 75% feed) at the beginning of the cut. The aim is to eliminate vibrations and the load of the blade teeth at the beginning of the cut. The cutting feed is constant during the cut, 15mm before the end of the cut the systems reduces the cutting feed automatically. Higher bladelife is achieved. Controlling system in CARBIDE regime uses the regulation of the cutting feed during excessive load of the blade (systems reads the load of the blade drive in Ampers). The regualtion is not active, it serves as a fuse if the blade is not worn out. The controlling system reduces the cutting feed to one half and finishes the cut. 
• The regulation of the cutting feed is realized by a hydraulic valve controlled by servoengine. Thanks to this a very precise cut is achieved. The operator inserts the desired cutting feed (mm/min)  into the programm  and the machine sets this feed very exactly. This way of control depends on the temperature (viscosity ) of hydraulic oil. 
• A controlling systém of machine represents a working states as circumferential blade speed, speed of arm movement to cut and a state of single working movements. A part of a system are also inputs and outputs for connection of an abovestandard accessories.
• New safe Siemens model with autodiagnostics.
• Working movements are regulated by hydraulic system. There are regulation valves for setting a vice pressure in hydraulic systém.

Basic equipment:

• light above the working place
• frequency converter
• blade
• set of tools
• manual instructions

The operator chooses one of two regimes:
- MANUAL: the machine cuts the material immediatelly in a semiautomatic regime.
- PROGRAM: the operator sets the cutting programm, machine realizes these programms, it is possible to make 99 different programms.The part of one programm is a complete setting of the cut: blade speed, feed speed, setting of an automatic regulation, setting of the hight of the bar to be cut, setting of the lenght of the bar and number of pieces. The lenght and number of pieces it is possible to set in 99 lines, the machine feeds differently set lenghts automatically. "
The machine enables to work with two cycles of material feeding.
- SEMIAUTOMATIC CYCLE: is recommended for this machine. The operator uses the feeder of the machine for the manipulation with the material and for the exact feed of the material into the cutting zone. The feeder helps the main vice to fix the material.  The movement of the feeder is realized by manual buttons or by GTO function. After starting GTO function the operator sets the position of the feeder, presses START button and feeder goes to the set position.
- AUTOMATIC CYCLE: the feeder feeds the material according to the set programm. Start of the automatic cycle is possible when it is  possible to fix the material into the jaws of the firm vice.   "

Operating cycle:
After starting the machine, vices are clamped automatically, cut is made by selected cutting speed, in the end position microswitch is on, arm goes to selected up position and vices open automatically.  The material is moved by the feeder – periodic regime ( feeder moves between zero position and the position of the set lenght of feed)  or consecutive regime ( feeder moves to the value of 700 mm) and clamps the material and feed it to the cut consecutively.